Multi-camera vision system for a vehicle

ABSTRACT

A multi-camera vision system for a vehicle includes a rear-mounted video camera, a front-mounted video camera, and first and second side-mounted video cameras at respective sides of the vehicle. Captured image data is processed at a central data processor to generate video images for display on a video screen. The captured image data is processed at the central data processor in order to detect objects that are within the combined field of view of the video cameras. At least one non-visual sensor captures sensor data in a region external of the vehicle and the captured sensor data is provided to the central data processor. An alert to the driver of the equipped vehicle is generated when, via processing at the central data processor of at least one of received image data and received sensor data, a potential hazard is determined to exist.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 14/641,812, filed Mar. 9, 2015, now U.S. Pat. No. 9,183,749,which is a continuation of U.S. patent application Ser. No. 14/551,608,filed Nov. 24, 2014, now U.S. Pat. No. 8,976,247, which is acontinuation of U.S. patent application Ser. No. 14/293,487, filed Jun.2, 2014, now U.S. Pat. No. 8,896,700, which is a continuation of U.S.patent application Ser. No. 13/285,128, filed Oct. 31, 2011, now U.S.Pat. No. 8,743,203, which is a continuation of U.S. patent applicationSer. No. 11/226,628, filed Sep. 14, 2005 (abandoned), which claims thebenefit of U.S. provisional application Ser. No. 60/692,113, filed Jun.20, 2005; Ser. No. 60/677,990, filed May 5, 2005; Ser. No. 60/653,787,filed Feb. 17, 2005; Ser. No. 60/642,227, filed Jan. 7, 2005; Ser. No.60/638,250, filed Dec. 21, 2004; Ser. No. 60/624,091, filed Nov. 1,2004, and Ser. No. 60/609,642, filed Sep. 14, 2004, which are all herebyincorporated herein by reference in their entireties. And U.S. patentapplication Ser. No. 14/641,812 is a continuation-in-part of U.S. patentapplication Ser. No. 14/211,256, filed Mar. 14, 2014, now U.S. Pat. No.9,014,966, which is a continuation of U.S. patent application Ser. No.14/033,963, filed Sep. 23, 2013, now U.S. Pat. No. 8,676,491, which is acontinuation of U.S. patent application Ser. No. 13/621,382, filed Sep.17, 2012, now U.S. Pat. No. 8,543,330, which is a continuation of U.S.patent application Ser. No. 13/399,347, filed Feb. 17, 2012, now U.S.Pat. No. 8,271,187, which is a continuation of U.S. patent applicationSer. No. 13/209,645, filed Aug. 15, 2011, now U.S. Pat. No. 8,121,787,which is a continuation of U.S. patent application Ser. No. 12/908,481,filed Oct. 20, 2010, now U.S. Pat. No. 8,000,894, which is acontinuation of U.S. patent application Ser. No. 12/724,895, filed Mar.16, 2010, now U.S. Pat. No. 7,822,543, which is a continuation of U.S.patent application Ser. No. 12/405,614, filed Mar. 17, 2009, now U.S.Pat. No. 7,711,479, which is a continuation of U.S. patent applicationSer. No. 11/935,800, filed Nov. 6, 2007, now U.S. Pat. No. 7,571,042,which is a continuation of U.S. patent application Ser. No. 11/624,381,filed Jan. 18, 2007, now U.S. Pat. No. 7,490,007, which is acontinuation of U.S. patent application Ser. No. 10/645,762, filed Aug.20, 2003, now U.S. Pat. No. 7,167,796, which claims priority of U.S.provisional application Ser. No. 60/406,166, filed Aug. 27, 2002; Ser.No. 60/405,392, filed Aug. 23, 2002; and Ser. No. 60/404,906, filed Aug.21, 2002.

FIELD OF THE INVENTION

The present invention relates to interior rearview mirror assembliesand, more particularly, to a method of making a mounting assembly for aninterior rearview mirror assembly.

BACKGROUND OF THE INVENTION

Mounting arrangements or assemblies for mounting an interior rearviewmirror assembly to an interior portion of a vehicle typically include amounting arm that is pivotally attached to the mirror assembly and/or toa channel mount or mounting base, which in turn mounts to the interiorportion of the vehicle. For example, a typical mounting assembly mayinclude a mounting arm with a ball member or spherical member or portionat each end, with one end being pivotally received in a socket at themirror assembly (or at a toggle portion of the mirror assembly for aprismatic mirror) and the other end being pivotally received in a socketat the mounting channel, which may be secured to a mounting button orthe like at the interior surface of the windshield of the vehicle.

Typically, the ball members of the mounting arm are pressed into therespective sockets, such as via a machine or the like, to insert theball member through the narrowed end of the socket and to secure theball members within the sockets. The ball members are typically metallicelements received within polymeric sockets and biased via a biasingmember or spring to provide the desired clamping or degree of resistanceof pivotal movement of the ball member relative to the socket.

A variety of interior and exterior mirror assemblies with indicators areknown in the art, such as U.S. Pat. Nos. 5,788,357; 6,257,746;6,005,724; 5,481,409; 6,512,624; 6,356,376; 2,263,382; 2,580,014;3,266,016; 4,499,451; 4,588,267; 4,630,904; 4,623,222; 4,721,364;4,906,085; 5,313,335; 5,587,699; 5,575,552; 5,938,320 and 5,786,772,Canadian Pat. No. CA 1,063,695, Pat. Abstracts of Japan Publication No.0917573, published Jul. 8, 1997, which are all hereby incorporatedherein by reference.

SUMMARY OF THE INVENTION

The present invention provides a mounting assembly that includes amounting arm and a channel mount or mounting base and/or a mirror socketor toggle portion. The mounting arm may comprise a polymeric materialand the channel mount and/or toggle portion is overmolded around therespective ball member. The mounting assembly thus may be formed via oneor more molding processes, and obviates the need to press the ballmembers into the respective socket portions. Optionally, electricalconducting elements, such as wire harnesses or lead frames, may beincluded, preferably by insert molding, within the mounting arm and mayextend from the mounting arm for connection to electrical components orleads, such as to a vehicle or accessory wiring harness and/or a circuitboard or other electrical elements. Optionally, the mounting base (thatattaches to a portion of the vehicle interior, such as to a mirrormounting button or similar attachment element adhered to an inner-cabinsurface of the vehicle windshield or to a header portion proximate thejoin of the windshield to the roof region of the vehicle) may beovermolded via insert molding onto a metallic insert that may have themounting structure for mounting to the mounting button or the like atthe windshield of the vehicle.

According to an aspect of the present invention, a method of making amounting assembly of an interior rearview mirror assembly includesproviding a mounting arm having at least one ball member at at least oneend thereof and molding at least one of a mounting base portion and amirror mounting portion over the at least one ball member.

The ball member is pivotally received in the mounting base portionand/or mirror mounting portion after the mounting base portion and/ormirror mounting portion is molded and cured. The at least one ballmember may comprise a first ball member at one end of the mounting armand a second ball member at the other end of the mounting arm. Themounting base portion may be molded over the first ball member and themirror mounting portion may be molded over the second ball member.

Optionally, the pivot joints may provide different torque thresholds forpivoting the mirror mounting portion about the mounting arm or themounting arm about the mounting base portion. In one form, the mountingbase portion may comprise a first material and the mirror mountingportion may comprise a second material, whereby the first material isdifferent than the second material. In another form, the first ballmember may have a first surface characteristic and the second ballmember may have a second surface characteristic, whereby the firstsurface characteristic is different than the second surfacecharacteristic.

Optionally, a channel element may be molded at least partially withinthe mounting base portion. Optionally, and for applications of themounting assembly with prismatic mirror assemblies, the mirror mountingportion may comprise a toggle portion.

Optionally, the mirror mount portion may have a metallic element insertmolded therein to provide the mounting structure for the mirrorassembly. Optionally, the mounting or support arm may include electricalconductors insert molded therein and at least partially therealong,whereby the conductors may electrically connect to an electrical elementat the mounting portion and/or at the mirror casing or reflectiveelement. The mounting portion may include a socket or pocket forreceiving a connector or plug of the vehicle wire harness, whereby theconnector of the vehicle wire harness may connect to a mirror wireharness that includes wiring that extends through and/or along themounting arm and into the mirror casing to a circuit board or the likewithin the mirror casing, such as at the reflective element of themirror. The pocket includes side and front and rear walls or portionsthat substantially encompass and define the pocket region or receivingportion and that substantially conceal the connectors of the wireharness from viewing by a person in or at the vehicle.

According to another aspect of the present invention, a mirror assemblyincludes a reflective element and a support element for supporting andat least partially encasing the reflective element. The reflectiveelement is received at least partially within a pocket or receivingportion or cavity of the support element. The support element preferablysubstantially retains the reflective element within the cavity via a lipportion that extends at least partially around the perimeter edge regionof the front surface (the viewable surface of the reflective elementthat is viewable by the driver of the vehicle when the mirror assemblyis installed in the vehicle) of the mirror assembly.

Optionally, the support element may comprise a substantially or at leastpartially flexible elastomeric element that may flex to allow thereflective element to be inserted into the cavity and may substantiallyreturn to its initial form (and may be biased to return to its initialform) to retain the reflective element within the support element.Optionally, the support element may be molded over and around theperimeter edge regions of the reflective element to substantiallyencompass the perimeter of the reflective element.

The support element may at least partially or substantially cover therear surface of the reflective element (the surface opposite to thefront surface and facing away from the driver of the vehicle when themirror assembly is installed in the vehicle) to provide a back plate orcover or support portion. The support element may include attachmentelements or tabs or the like at the rear or back support portion, suchas for mounting or attaching a back plate to the reflective element andsupport element assembly.

The back support portion may include openings or apertures therethrough,such as for establishing electrical connections between the back plate(and circuitry or circuit board on the back plate) and electricalconnections of the reflective element (such as fourth surface bus-barconnections for an electro-optic or electrochromic reflective element orcell), and/or for providing viewing apertures for display information tobe displayed by a display device (at the circuitry or circuit board onthe back plate) and through the viewing aperture and through thereflective element so as to be viewable by the driver of the vehicle atthe reflective element.

Therefore, the present invention provides a unitarily molded or formedmounting assembly, with the toggle portion or mirror mounting portionand/or the channel mount or mounting base portion molded over the endsof the mounting arm. The mounting arm may include a ball member orpartial ball member at one or both ends for pivotally attaching themounting arm to the mirror mounting portion and/or the mounting baseportion when the mirror mounting portion and/or the mounting baseportion is/are molded over the ball members of the mounting arm. Themolded or pre-formed mounting arm may be inserted or loaded into a moldand the toggle portion and channel mount may be molded over the ends ofthe mounting arm to form the mounting assembly via a unitary moldingprocess. The pivot joints defined by the ball members and overmoldedportions may provide different frictional resistance to providedifferent threshold torques for pivoting the mirror assembly or mountingarm about the respective pivot joints. For example, the mountingassembly may provide different surface conditions at the ball members ordifferent materials of the mirror mounting portion and the mounting baseportion to provide different torques at the pivot joints of the mountingassembly. The present invention thus provides for in mold forming of asocket around a ball member that is pre-formed and inserted into themold cavity.

The present invention also provides a plastic mounting base formed bymolding of a polymeric resin that preferably is overmolded over ametallic insert (that itself may be structurally adapted to at leastpartially cooperate with a structure on an attachment member, such as amirror mounting button, to which the mounting base mounts) to providestructural integrity and the desired exterior appearance or surface tothe mounting base. The polymeric-material or plastic support arm mayinclude a wire or electrical conductor insert molded therein and atleast partially therealong, whereby the conductors may connect tocircuitry or accessories or a wiring harness at the mounting base and tocorresponding circuitry or accessories within the mirror. Theaccessories or circuitry of the mounting base may be within the mountingbase and generally along the longitudinal axis of the support arm, suchthat the base is not readily viewable by the driver of the vehicle. Theelectrical connections may be readily made as the mirror supportassembly is assembled and as the mirror assembly is installed in thevehicle.

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an interior rearview mirror assemblyincorporating the mounting assembly of the present invention;

FIG. 2 is a perspective view of a mounting assembly in accordance withthe present invention;

FIG. 3 is another perspective view of the mounting assembly of FIG. 2;

FIG. 3A is a perspective view of another mounting assembly of thepresent invention;

FIG. 3B is an opposite perspective view of the mounting assembly of FIG.3A;

FIG. 4 is a perspective view of a mounting arm suitable for use with themounting assembly of the present invention;

FIG. 5 is a sectional view of another mounting assembly in accordancewith the present invention;

FIG. 6 is a sectional view of another mounting assembly in accordancewith the present invention;

FIG. 7 is a sectional view of another mounting assembly in accordancewith the present invention;

FIG. 8 is a sectional view of another mounting assembly in accordancewith the present invention;

FIG. 9 is a sectional view of a mounting member with an electricalconductor insert molded within the mounting member;

FIG. 10 is a sectional view of another mounting assembly in accordancewith the present invention;

FIG. 11 is a sectional view of another mounting assembly in accordancewith the present invention

FIG. 12 is a sectional view of another mounting assembly in accordancewith the present invention;

FIG. 13 is a sectional view of a mounting attachment of the presentinvention;

FIG. 14 is a sectional view of another mounting member in accordancewith the present invention;

FIG. 15 is a sectional view of a mirror assembly incorporating themounting member of FIG. 14;

FIG. 16 is a sectional view of another mirror assembly incorporatinganother mounting arrangement in accordance with the present invention;

FIG. 17 is a partial sectional view of a mirror assembly incorporatinganother mounting arrangement in accordance with the present invention;

FIG. 18 is a partial sectional view of a mirror assembly incorporatinganother mounting arrangement in accordance with the present invention;

FIG. 19 is an exploded perspective view of another mounting arrangementin accordance with the present invention;

FIG. 20 is a side elevation of the mounting arrangement of FIG. 19;

FIG. 21 is a sectional view of the mounting arrangement of FIG. 20;

FIG. 21A is a side elevation of another mounting arrangement inaccordance with the present invention;

FIG. 22 is a sectional view of a mirror assembly and reflective elementassembly in accordance with the present invention;

FIG. 23 is a plan view of the front substrate of the reflective elementassembly of FIG. 22;

FIG. 24 is a sectional view of the front substrate taken along the lineXXIV-XXIV in FIG. 23;

FIG. 25 is a sectional view of an reflective element and support elementassembly in accordance with the present invention;

FIG. 26 is a sectional view of another reflective element and supportelement assembly in accordance with the present invention;

FIG. 27 is a sectional view of another rearview mirror assembly inaccordance with the present invention;

FIG. 28 is a sectional view of an interior rearview mirror assemblyincorporating a laser display device in accordance with the presentinvention;

FIG. 29 is a perspective view of an interior rearview mirror assemblymounted on a mounting arrangement in accordance with the presentinvention;

FIG. 30 is an exploded perspective view of the mounting arrangement ofFIG. 29;

FIG. 31 is another exploded perspective view of a mounting arrangementof the present invention;

FIG. 32 is a block diagram of a display control system in accordancewith the present invention;

FIG. 33 is a side elevation exploded view of a reflective elementassembly having a reflective element, back plate and circuit board inaccordance with the present invention;

FIG. 34 is a forward facing view of a powered sun visor with videoscreen incorporated therein in accordance with the present invention,shown with the sun visor flipped or pivoted downward;

FIG. 35 is a front elevation of an exterior mirror reflective elementwith a turn signal display formed thereon;

FIG. 36 is a sectional view of a portion of the reflective element ofFIG. 35;

FIGS. 37A and 37B are enlarged views of different spacings of holes inthe coating layer suitable for the display of FIGS. 35 and 36;

FIG. 38 is a table of light transmission ratio of a display for varioussizes and spacings of scratches/holes in the reflector coating;

FIG. 39 is a sectional view of another reflective element in accordancewith the present invention;

FIG. 40 is a sectional view of another reflective element in accordancewith the present invention; and

FIG. 41 is a side elevation of an interior rearview mirror assembly andvideo display module in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depictedtherein, an interior rearview mirror assembly 10 is pivotally oradjustably mounted to an interior portion of a vehicle, such as via adouble ball mounting or bracket assembly 12 (FIG. 1). Mirror assembly 10includes a prismatic reflective element 14, a bezel portion 16, ahousing or casing 18, and a mirror mounting portion 20, such as a toggleor flip mechanism or toggle portion, for pivoting or adjusting thereflective element 14 between a full reflectivity daytime position and areduced reflectivity nighttime position, as is known in the mirror art.The mounting or bracket assembly 12 adjustably mounts the reflectiveelement 14 to an interior portion of the vehicle, such as to an interiorsurface of a windshield of the vehicle or the like. Mounting assembly 12includes a mounting arm 22, and a mounting base portion or channel mount24 and toggle portion 20 molded over the respective ends of the mountingarm 22, as discussed below.

The mirror assembly may comprise a prismatic mirror assembly, such as aprismatic mirror assembly utilizing aspects described in U.S. Pat. Nos.6,318,870; 6,598,980; 5,327,288; 4,948,242; 4,826,289; 4,436,371 and4,435,042; and PCT Application No. PCT/US04/015424, filed May 18, 2004;and U.S. patent application Ser. No. 10/933,842, filed Sep. 3, 2004, nowU.S. Pat. No. 7,249,860, which are hereby incorporated herein byreference. Optionally, the prismatic reflective element may comprise aconventional prismatic reflective element or prism, or may comprise aprismatic reflective element of the types described in PCT ApplicationNo. PCT/US03/29776, filed Sep. 19, 2003; U.S. patent application Ser.No. 10/709,434, filed May 5, 2004, now U.S. Pat. No. 7,420,756; Ser. No.10/933,842, filed Sep. 3, 2004, now U.S. Pat. No. 7,249,860; Ser. No.11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451; Ser. No.10/528,269, filed Mar. 17, 2005, now U.S. Pat. No. 7,274,501; and/orSer. No. 10/993,302, filed Nov. 19, 2004, now U.S. Pat. No. 7,338,177,and/or PCT Application No. PCT/US2004/015424, filed May 18, 2004, whichare all hereby incorporated herein by reference, without affecting thescope of the present invention. A variety of mirror accessories andconstructions are known in the art, such as those disclosed in U.S. Pat.Nos. 5,555,136; 5,582,383; 5,680,263; 5,984,482; 6,227,675; 6,229,319and 6,315,421 (the entire disclosures of which are hereby incorporatedby reference herein), that can benefit from the present invention.Optionally, the mirror assembly may comprise an electro-optic orelectrochromic reflective element assembly, as discussed below.

Mirror casing 18 and bezel portion 16 may be formed from variousmaterials but are preferably molded from a resinous polymeric materialas is conventionally known in the industry. Reflective element or prism14 may also be formed from various materials such as plastic or glass orthe like, but preferably is glass, and may have a planar front surface14 a extending at an angle to a planar rear surface (not shown). Therear surface of the prism may be coated with a reflective layer of ametal or metal alloy, such as chromium, aluminum or alloys thereof, asis conventionally known in the industry.

Actuation or pivotal movement of the toggle tab 20 a of toggle portion20 pivots prism 14 relative to the mounting arm 22 of mounting assembly12 to pivot the reflective rear surface in order to reduce glare duringnighttime conditions, as discussed below. When reflective element 14 ispivoted from a full reflectivity day position to a reduced reflectivitynight position, the reflective surface is rotated such that the uncoatedfront surface 14 a is aligned for viewing by the vehicle driver insteadof the reflective rear surface. The reflective rear surface may reflectat least about 60 percent to 95 percent of the light incident thereon,while uncoated front surface 14 a may reflect about 4 percent of thelight incident thereon (or any other desired reflectivity commensuratewith the construction/coated first surface that is utilized), therebysignificantly reducing glare from headlights or other bright lights tothe rear of the vehicle to the driver's eyes.

In the illustrated embodiment, and as best shown in FIG. 4, mounting arm22 includes a shaft or arm portion 26, a ball member 28 at one end and aball member 30 at the other end. The ball member 30 comprises a partialball member, which allows for enhanced molding of the toggle portion 20around the ball member 30, as discussed below. Mounting arm 22 may bemolded of a polymeric material, such as an acetal or nylon material orthe like, or may comprise a metallic material. Optionally, the ballmembers 28, 30 may be molded or formed to have different surfacetextures from one another, so as to provide different torques at thedifferent pivot joints of the mirror assembly, as discussed below.

Mounting base portion or channel mount 24 may mount or attach to amounting member at the interior portion of the vehicle, such as to amounting button or the like at the interior surface of the windshield.The mounting button may be secured, such as by bonding or by a suitableadhesive, to an interior surface of a vehicle windshield, and may be aconventional mounting button or base member, such as the type disclosedin commonly assigned U.S. Pat. No. 4,936,533, issued to Adams et al.,the disclosure of which is hereby incorporated herein by reference, or abreakaway mount such as the type disclosed in commonly assigned U.S.Pat. No. 5,820,097, issued to Spooner; or U.S. Pat. No. 5,100,095,issued to Haan et al., the disclosures of which are hereby incorporatedherein by reference.

Channel mount 24 may comprise a molded element formed of a polymericmaterial, such as a polyolefin polymeric material, such as apolypropylene and/or polyethylene polymeric resinous material or thelike. Channel mount 24 may have a socket portion 25 molded over and atleast partially around ball member 28 of mounting arm 22 to pivotallyattach mounting arm 22 to channel mount 24. Optionally, and desirably,channel mount 24 may be molded over and at least partially around ametallic channel element 32 (FIG. 3), whereby the metallic channelelement 32 provides sufficient and desired rigidity to secure thechannel mount to the mounting button or the like at the windshield ofthe vehicle. As shown in FIGS. 3A and 3B, a mirror mount 24′ may bemolded over a metallic channel element 32′ and may have a socket portion25′ molded over the ball member of the support arm 22. The metallicchannel element 32′ may comprise a metallic stamping and may include ametallic clip or tab 32 a′ for retaining the mount and channel elementto the mounting button on the interior surface of the vehicle windshield(or elsewhere in the vehicle).

Mirror mounting portion or toggle portion 20 may also comprise a moldedelement formed of a polymeric material, such as a polyolefin polymericmaterial, such as a polypropylene and/or polyethylene polymeric resinousmaterial or the like. Toggle portion 20 may be molded over and at leastpartially around ball member 30 of mounting arm 22 to pivotally attachtoggle portion 20 to mounting arm 22. Toggle portion 20 may beadjustably mounted to an attachment plate or the like at the rearsurface of the prism 14, such as described in U.S. Pat. No. 6,318,870;and/or U.S. patent application Ser. No. 10/933,842, filed Sep. 3, 2004,now U.S. Pat. No. 7,249,860, which are hereby incorporated herein byreference. The toggle portion may include the toggle tab 20 a, or mayinclude a rotary flip mechanism (such as described in U.S. Pat. No.6,329,925; and/or U.S. patent application Ser. No. 10/933,842, filedSep. 3, 2004, now U.S. Pat. No. 7,249,860, which are hereby incorporatedherein by reference), or the like, without affecting the scope of thepresent invention.

Mounting arm 22 of mounting assembly 12 thus may be formed of a rigidpolymeric or metallic material, and the channel mount 24 and/or toggleportion 20 may be molded over and at least partially around therespective ball members 28, 30 of mounting arm 22 to provide a unitarilyformed mounting assembly. The material for the mounting arm 22 isselected to be a material (such as a metallic material or a polymericmaterial) that can withstand the overmolding process and that allows forthe overmolded portions to break free from the surfaces of the ballmembers after the portions are overmolded and cured. Optionally, theball members of the mounting arm may be coated with a coating or layerthat eases the breakaway or loosening of the overmolded portions fromthe surface of the ball members.

During the molding process, the pre-formed mounting arm 22 may be loadedor inserted into a mold cavity, with the ball members received inrespective cavities for molding the toggle portion and channel mount.The polymeric material of the toggle portion and/or the channel mountmay be injected or shot into the respective mold cavity to mold theportion around the respective ball member or partial ball member of themounting arm. The channel element may be loaded or inserted into thechannel mount mold cavity and thus may be insert molded into the channelmount as the channel mount is molded over the ball member 28 of themounting arm 22. The channel mount and toggle portion may be molded viaa single molding operation or may be molded via separate moldingoperations, and may comprise different materials (as discussed below),depending on the particular application of the mounting assembly.

The partial ball member 30 at the toggle end of the mounting arm 22allows the mold to close around the shaft portion of the mounting armand against the annular surfaces 30 a of the partial ball member 30.This may reduce the amount of excess mold material or flash that mayresult from the mold closing on the spherical surface of a sphericalball member. Optionally, the ball member 28 may be formed as a partialball member as well, without affecting the scope of the presentinvention.

Optionally, and desirably, the torque required to pivot the channelmount about the ball member 28 may be different than the torque requiredto pivot the toggle portion about the partial ball member 30. Forexample, the torque at the toggle portion may be less than the torque atthe channel mount, so that a user of the mirror assembly may readilyadjust the angle of viewing of the mirror assembly without repositioningthe mirror assembly relative to the vehicle (such as may occur viapivoting the mounting arm relative to the channel mount). Furthermovement to overcome the frictional resistance at the channel mount mayreposition the mirror assembly to the desired position. In order toachieve a greater torque at the mount joint over the torque at themirror joint, the diameter of the ball members at the ends of thesupport arm may be different. Preferably, the diameter of the ballmember at the mirror mount is at least about 20 percent (and morepreferably at least about 25 percent and most preferably at least about30 percent) greater than the diameter of the ball member at the mirroror toggle or back plate. For example, the diameter of the ball member atthe mirror or toggle or back plate may be approximately 14-18 mm, whilethe diameter of the opposite ball member at the mirror mount may beapproximately 20-25 mm.

Optionally, in order to provide different torques, the surface textureor surface condition of the ball members 28, 30 may be different toprovide a different frictional resistance at each end of the mountingarm. For example, the ball member 28 may be stippled or otherwisetextured or roughened, while the partial ball member 30 may be lessstippled or textured or may be substantially smooth, such that thefrictional resistance at the partial ball member 30 is less than thefrictional resistance at the ball member 28. Thus, the surfaces of theball members may be textured, such as, for example, by providing an EDMtextured finish (such as known in the tooling arts) as formed by themold tool. Alternately, or additionally, it is envisioned that theselected materials for the channel mount and the toggle portion may bedifferent to provide different clamping forces or different frictionalresistance at the respective ball members or pivot joints of themounting assembly. Optionally, the wall/section thickness of the socketor receiving portions of the toggle or back plate and/or the mirrormount may be selected to provide the desired clamping pressure to therespective ball member to achieve the desired torques at the respectivejoints. For example, the socket portions may be molded over therespective ball members, whereby the thickness of the walls of thesocket portions affects how much pressure the socket portion will applyto the respective ball member as the socket portion cools and shrinksafter overmolding and upon exit from the mold. For example, a thickersocket wall thickness will apply a greater pressure on the ball memberas the overmolded socket portion cools and shrinks as compared to athinner socket wall thickness. Other means for providing differentresistance or different torque at the pivot joints of the mountingassembly may be implemented, without affecting the scope of the presentinvention.

The differential torques at the respective pivot joints may thus beestablished by material selection and/or mechanical design. Preferably,the support arm is formed of a substantially stiff resin material thatdoes not appreciably shrink after injection molding, so that the desiredsubstantially uniformly defined and predicted spherical ball surface maybe achieved. Preferably, the linear mold shrinkage, parallel (such asmeasured via ISO 294-4) is less than about 0.006 cm/cm, and morepreferably less than about 0.004 cm/cm, and most preferably less thanabout 0.0025 cm/cm. Preferably, the linear mold shrinkage, transverse(such as measured by ISO 294-4) is less than about 0.015 cm/cm, and morepreferably less than about 0.012 cm/cm, and most preferably less thanabout 0.01 cm/cm. It is also desirable that the selected material have ahigh flexural modulus, such as determined using ISO 178. Preferably, theflexural modulus is at least about 9 GPa, and more preferably at leastabout 11 GPa, and most preferably at least about 13 GPa. For example, aglass filled or glass reinforced Nylon material, such as DSM Akulon®Ultraflow™ K-FG) Nylon No. 6, 50 percent glass reinforced molding resinmay be used. Such a material has a linear mold shrinkage, parallel, ofabout 0.002 cm/cm; a linear mold shrinkage, transverse, of about 0.009cm/cm; and a flexural modulus of about 14 GPa.

Clearly, other filled or reinforced resinous polymeric materials may beused to achieve the desired results, without affecting the scope of thepresent invention. For example, a polybutylene terephthalate (PBT)filled/reinforced thermoplastic polyester resin may be used. Preferably,the material is at least about 20 percent glass/mineral filled, and morepreferably at least about 25 percent glass/mineral filled, and mostpreferably at least about 30 percent glass/mineral filled. Such amaterial may provide a flexural modulus of about 9.5 GPa and a linearmold shrinkage in the flow direction of about 0.003 cm/cm. The materialtype and grade for the support arm thus may be selected to achieve thedesired load and shrinkage factors or parameters and the desired colorand surface finish of the support arm and ball members at opposite endsthereof.

The material selected for the mount and the toggle or back platepreferably has a selected shrinkage factor so that the overmolded socketportions may shrink around the ball members to retain and frictionallyengage the ball members therein (however, should the construction bereversed so that the support arm comprises the sockets and the mountand/or toggle have the ball member, then the material selections may bereversed accordingly). Preferably, the mount material comprises amaterial that has at least about four times the amount of post-moldingshrinkage over the material selected for the support arm (and morepreferably at least about six times the amount of shrinkage and mostpreferably at least about eight times the amount of shrinkage). Forexample, the mount may be molded from an acetal resin, such as a TiconaCelcon® M90™ UV acetal copolymer having a flexural modulus of about 2.6GPa (as determined by ASTM D790), and a linear mold shrinkage, parallelof about 0.022 cm/cm and a linear mold shrinkage, transverse of about0.018 cm/cm. Other materials may be selected, including a filledpolypropylene or other polymer resins with suitable mechanical andshrinkage properties, without affecting the scope of the presentinvention.

The toggle or backing plate may be molded over the ball member of thesupport arm and may also comprise a material that has a greatershrinkage factor than the support arm. For example, the overmoldedtoggle (which may include a flexible living hinge or the like) maycomprise a polypropylene homopolymer or a polypropylene with a glassfiber filler. For example, the toggle may comprise a polypropylenehomopolymer having a linear mold shrinkage in the range of about 0.025to about 0.235 cm/cm (ASTM D956), and a flexural modulus in the range ofabout 1.35 GPa to about 1.65 GPa (ASTM D790). For example, a BasellPolyolefin grade Pro-fax 6523 general purpose polypropylene homopolymerresin (which is available in natural and custom compounded colors) maybe used to mold the toggle. Optionally, the toggle may comprise apolypropylene with ten percent glass fiber filler having a linear moldshrinkage of about 0.007 cm/cm (ASTM D956) and a flexural modulus ofabout 2.4 GPa (ASTM D790). Optionally, the toggle may comprise apolypropylene with twenty percent glass fiber filler having a linearmold shrinkage of about 0.004 cm/cm (ASTM D956) and a flexural modulusof about 3.6 GPa (ASTM D790). Optionally, the toggle may comprise apolypropylene with thirty percent glass fiber filler having a linearmold shrinkage of about 0.003 cm/cm (ASTM D956) and a flexural modulusof about 5.6 GPa (ASTM D790). The stiffer materials, such as an acetalor a filled polypropylene may be more preferred for non-prismatic toggleor back plate members, such as back plates for electro-optic reflectiveelement applications.

Optionally, the mounting arm of the mounting assembly may include apassageway therethrough for routing wiring or the like through the armto provide electrical communication between the electronic circuitryelement or printed circuit board or accessory of the mirror assembly andcircuitry or accessories or power source of an accessory module or ofthe vehicle. For example, the mounting assembly may utilize principlesdescribed in U.S. patent application Ser. No. 10/032,401, filed Dec. 20,2001, published Jul. 11, 2002 as U.S. Pat. Publication No.US2002/0088916, now U.S. Pat. No. 6,877,709; and/or PCT Application No.PCT/US2004/015424, filed May 18, 2004, which are hereby incorporatedherein by reference, or may utilize electrical connection principles ofthe type described in International Publication No. WO 2003/095269,published Nov. 20, 2003; and/or U.S. patent application Ser. No.10/512,206, filed Oct. 22, 2004, now U.S. Pat. No. 7,110,156, which arehereby incorporated herein by reference. Optionally, the mounting armpassageway may allow for infrared or visible light to be transmittedalong the tube or arm to communicate signals to or from the mirrorassembly. In such applications, the arm or mounting assembly may includereflectors or mirrored surfaces to guide and reflect the light betweenthe source and receiver, and may adjust the reflectors to accommodateadjustment of the mirror head assembly relative to the mounting base.The mounting arm thus may provide a light conduit or path or pipe forlight signals to be communicated or guided or directed to providecommunication between the accessory module or pod and the interiorrearview mirror assembly. Other means for providing electrical powerand/or control to the electronic circuitry element or circuitry boardand/or accessories of the mirror assembly may be implemented withoutaffecting the scope of the present invention.

Although shown and described as a double ball mounting assembly, it isenvisioned that a single ball or single joint mounting assembly (such asa single joint assembly of the types described in U.S. Pat. No.6,483,438 and/or PCT Application No. PCT/US2004/015424, filed May 18,2004, which are hereby incorporated herein by reference) may be formedin a similar manner, without affecting the scope of the presentinvention. For example, the toggle portion may be molded over the ballmember of a mounting arm in a similar manner as described above, whilethe other end of the mounting arm may be insert molded into a channelmount so that the mounting arm extends from the channel mount in asubstantially rigid or non-moving manner. Optionally, the channel mountand mounting arm may be integrally or unitarily formed as a singleelement, without affecting the scope of the present invention. Thechannel mount and mounting arm element may comprise a metallic materialor a polymeric material. If the channel mount and mounting arm elementcomprises a polymeric material, a metallic channel element may be insertmolded into the channel mount as described above.

Although shown and described as including a toggle portion for aprismatic mirror assembly, the mounting assembly of the presentinvention may include a mounting or attaching portion for attaching toan electro-optic mirror assembly, such as to an electrochromicreflective element assembly or cell of an electrochromic mirrorassembly, without affecting the scope of the present invention. Forexample, the attaching portion may utilize aspects of the assembliesdescribed in U.S. Pat. Nos. 6,690,268; 6,483,438 and 6,593,565; and/orU.S. patent application Ser. No. 10/933,842, filed Sep. 3, 2004, nowU.S. Pat. No. 7,249,860, which are hereby incorporated herein byreference. In such applications, the backing plate or mounting plate maycomprise a filled polypropylene or acetal or other suitable polymericmaterial.

The interior rearview mirror assembly may comprise an electro-optic orelectrochromic reflective element or cell, such as an electrochromicmirror assembly and electrochromic reflective element utilizingprinciples disclosed in commonly assigned U.S. Pat. Nos. 6,690,268;5,140,455; 5,151,816; 6,178,034; 6,154,306; 6,002,544; 5,567,360;5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673; 5,073,012;5,117,346; 5,724,187; 5,668,663; 5,910,854; 5,142,407 and/or 4,712,879,and/or U.S. patent application Ser. No. 10/054,633, filed Jan. 22, 2002,now U.S. Pat. No. 7,195,381; and/or Ser. No. 11/021,065, filed Dec. 23,2004, now U.S. Pat. No. 7,255,451, which are all hereby incorporatedherein by reference, and/or as disclosed in the following publications:N. R. Lynam, “Electrochromic Automotive Day/Night Mirrors”, SAETechnical Paper Series 870636 (1987); N. R. Lynam, “Smart Windows forAutomobiles”, SAE Technical Paper Series 900419 (1990); N. R. Lynam andA. Agrawal, “Automotive Applications of Chromogenic Materials”, LargeArea Chromogenics: Materials and Devices for Transmittance Control, C.M. Lampert and C. G. Granquist, EDS., Optical Engineering Press, Wash.(1990), which are hereby incorporated by reference herein. The mirrorassembly may include one or more displays, such as the types disclosedin U.S. Pat. Nos. 5,530,240 and/or 6,329,925, which are herebyincorporated herein by reference, and/or display-on-demand ortransflective type displays, such as the types disclosed in U.S. Pat.Nos. 6,690,268; 5,668,663 and/or 5,724,187, and/or in U.S. patentapplication Ser. No. 10/054,633, filed Jan. 22, 2002, now U.S. Pat. No.7,195,381; Ser. No. 10/528,269, filed Mar. 17, 2005, now U.S. Pat. No.7,274,501; Ser. No. 10/533,762, filed May 4, 2005, now U.S. Pat. No.7,184,190; and/or Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S.Pat. No. 7,255,451; and/or PCT Application No. PCT/US03/29776, filedSep. 9, 2003; and/or PCT Application No. PCT/US03/35381, filed Nov. 5,2003; and/or U.S. provisional application Ser. No. 60/630,061, filedNov. 22, 2004; Ser. No. 60/667,048, filed Mar. 31, 2005; Ser. No.60/629,926, filed Nov. 22, 2004; Ser. No. 60/531,838, filed Dec. 23,2003; Ser. No. 60/553,842, filed Mar. 17, 2004; and Ser. No. 60/563,342,filed Apr. 19, 2004, and/or PCT Application No. PCT/US03/40611, filedDec. 19, 2003, which are all hereby incorporated herein by reference, ormay include or incorporate video displays or the like, such as the typesdescribed in PCT Application No. PCT/US03/40611, filed Dec. 19, 2003,and/or U.S. provisional application Ser. No. 60/630,061, filed Nov. 22,2004; and Ser. No. 60/667,048, filed Mar. 31, 2005, which are herebyincorporated herein by reference. The thicknesses and materials of thecoatings on the substrates of the electrochromic reflective element,such as on the third surface of the reflective element assembly, may beselected to provide a desired color or tint to the mirror reflectiveelement, such as a blue colored reflector, such as is known in the artand/or such as described in U.S. Pat. Nos. 5,910,854 and 6,420,036, andin PCT Application No. PCT/US03/29776, filed Sep. 9, 2003, which are allhereby incorporated herein by reference. The mirror may include or beassociated with driver circuitry for driving/controlling theelectro-optic or electrochromic reflective element or cell, such asdriver circuitry of the types described in U.S. Pat. No. 6,447,124and/or U.S. patent application Ser. No. 10/456,599, filed Jun. 6, 2003,now U.S. Pat. No. 7,004,593, and/or Ser. No. 11/201,661, filed Aug. 11,2005, now U.S. Pat. No. 7,480,149, which are hereby incorporated hereinby reference.

Optionally, the plastic mirror mount or base and socket may be unitarilymolded from a polymeric resin to form the base for mounting to themirror mounting button or the like at the windshield and the socket forreceiving the ball of the mounting or support arm. The mirror mount maybe molded over a metallic insert or the like so as to provide apolymeric outer coating or portion, while providing the stiffness andrigidity of the metallic element. Portions of the mirror mount or basethat engage, for example, a mirror mounting button attached to thevehicle windshield, may thus be metal [or metal with only a thin layerof polymeric material molded over; this thin layer however provides acosmetic utility (thus an unpainted metal zinc die-cast can be used asthe metal insert but the thin polymeric layer gives it a color andappearance matching the rest of the molded mirror mount or base)].However, other portions of the mirror mount or base that engage themirror mounting button attached to the vehicle windshield may be molded(of the polymeric resin used to form the overall mirror mount or base)to form a mirror-button engaging element or structure, such as a plasticlip or tongue. Thus, one aspect of the present invention comprises thecombination formed via insert/overmolding of metal-likeproperty/structure and plastic/polymeric-like property/structure for atleast the mirror mount or base.

For example, and with reference to FIG. 5, a mirror assembly 110 ispivotally or adjustably mounted to an interior portion of a vehicle,such as via a double ball mounting or bracket assembly 112. Mirrorassembly 110 includes a reflective element 114, a polymeric-materialhousing or casing 118, and mirror socket 120. The mounting or bracketassembly 112 adjustably mounts the mirror casing 118 and/or reflectiveelement 114 to an interior portion of the vehicle, such as to aninterior surface of a windshield of the vehicle or the like. Mountingassembly 112 includes a plastic mounting arm or support arm 122, and aplastic mounting base portion or channel mount 124. The plastic moldedball ends 122 a, 122 b of support arm 122 may be received withinrespective plastic molded sockets 124 a and 120 to pivotally mount themirror casing or reflective element to the base 124.

Support arm 122 comprises a polymeric support arm, such as a support armmolded or otherwise formed of an acetal material or the like. Thesupport arm 122 comprises a double ball arm with opposite ball membersor spherical portions 122 a, 122 b at opposite ends of an arm or shaftportion 122 c. As shown in FIG. 5, the ball member 122 a of support arm122 may be pivotally received within a socket 120 of casing 118 topivotally mount casing 118 to support arm 122, while the ball member 122b is pivotally received within a socket 124 a of mounting base 124.However, the support arm 122 may be pivotally attached to the casing ormay pivotally attach to a mounting or attachment or back plate at thereflective element or to a toggle member or the like, without affectingthe scope of the present invention. The reflective element 114 maycomprise a prismatic reflective element (whereby the support arm ispreferably attached to a toggle member, such as a toggle member of thetypes discussed above), or may comprise an electro-optic reflectiveelement, such as an electrochromic reflective element or the like(whereby the support arm is preferably attached to a plastic moldedattachment or back plate at the rear surface of the reflective element),without affecting the scope of the present invention.

Mounting base 124 includes the socket 124 a and a base portion 124 bintegrally molded or formed together, such as by injection molding, asknown in the molding arts. Base portion 124 b includes a polymericovermold portion 126 a that is molded over and at least partially arounda metallic insert portion 126 b. The metal insert 126 b may comprise ametallic material, such as a die-cast aluminum or zinc material, and mayprovide the channels or tabs or structure or the like for engaging andmounting to and cooperating with the mirror mounting button (not shown)or structure at the windshield of the vehicle (or to other mountingstructures of the vehicle). The mounting base thus provides the desiredmechanical quality and mounting structure via the metallic insert, andprovides the desired color and appearance (or texture or decorativeeffect) and resilience (particularly for the socket portion) via theovermolded plastic or polymeric portion. The mounting base provides thedesired qualities and characteristics with an integrally formedcomponent, which enhances the assembly process of the mirror assemblyand provides enhanced structural integrity of the mounting base andmounting assembly.

Optionally, the mirror assembly may include one or more electricalaccessories or elements, and may be connected to a power source and/orcontrol of the vehicle via connection to a wire harness of the vehicle.For example, and with reference to FIG. 6, a mirror assembly 110′ mayinclude a mounting assembly 112′ that includes a support arm 122′ withelectrical conductors or conductive elements 128 insert molded orintegrally molded within and at least partially along the support arm122′. The electrical conductors or conductive elements may compriseindividual conductive elements (such as metal wires or leads) separatedby the non-electrically conducting molded polymeric material of thesupport arm, or may comprise multi-wire wire harnesses (comprisingmultiple wires, each individually electrically insulated one fromanother) or cables, such as a ribbon cable or harness or the like,without affecting the scope of the present invention. The conductors maybe insert molded in the support arm while the support arm is beingformed, such as by injection molding, or may be fed through a passagewayformed in an already-molded support arm (for example, a multi-wireribbon or cable of individually insulated wires or leads may be threadedthrough or otherwise passed through a passageway formed or establishedin the support arm).

In the illustrated embodiment, the electrical conductors or conductiveelements 128 terminate at connectors 130 a, 130 b, such as multi-pinplugs or sockets at opposite ends of the conductors 128 for connectingor plugging the connectors to corresponding connectors (not shown) at orin the mirror casing 118 (such as at a circuit board or the like at themirror reflective element or otherwise within the mirror casing) or atthe mounting base 124. As shown in FIG. 6, the connector 130 a may bepositioned at the end of ball 122 a, and the socket 120′ (which may beformed at the casing or at a toggle member or attachment or back plateof the mirror) may have an opening formed at the end to accommodate theconnector and to provide clearance for movement of the connectorrelative to the socket when the mirror is pivoted or articulated aboutball 122 a. The other connector 130 b may be positioned at the supportarm for connecting to a wire or harness or cable or the like of thevehicle, such as to a wire harness extending from a headliner of thevehicle or the like. The connectors 130 a, 130 b may be connected to theconductive elements 128, and may include a flying lead or flexible leador wires between the ends of the conductive elements at the support armand the plugs or sockets at the ends of the connectors (so as to providesufficient slack to allow ball movement within the ball socket jointwithout placing strain on electrical connectors/connections). The mirrorassembly 110′ may otherwise be substantially similar to the mirrorassembly 110, discussed above, such that a detailed discussion of themirror assemblies will not be repeated herein. The common orsubstantially similar elements or components are shown in FIGS. 5 and 6with common reference numbers.

Optionally, the mounting base of the mounting assembly may include orincorporate an electrical accessory or element or circuitry that may beelectrically connected to a corresponding electrical accessory orelement or circuitry within the mirror casing. For example, and withreference to FIG. 7, a mirror assembly 210 may include an essentiallyall-polymeric or plastic mounting assembly 212 having a mounting base224 that houses or contains an electrical element or circuitry or sensor232, such as a compass sensor, such as a magneto-responsive sensor, suchas a magneto-resistive sensor, a magneto-capacitive sensor, amagneto-inductive sensor, a flux-gate sensor or a Hall-effect sensor orthe like. The sensor 232 may be positioned at and within the molded baseportion 226 a so that the sensor is substantially fixedly positionedwithin the vehicle when the mounting base is attached to the mountingbutton or structure of the vehicle. The sensor 232 may include a lead orwire or wires 234 with a connector 234 a, such as a multi-pin plug orsocket or the like, at an end thereof for connecting to a correspondingconnector or plug or socket 230 b of electrical conductors 230 ofsupport arm 222. The support arm 222 and electrical conductors 228,connectors 230 a, 230 b, mirror housing or casing 218 and socket 220 ofmirror assembly 210 may be substantially similar to the correspondingcomponents of mirror assembly 110′, discussed above, such that adetailed description of the common or similar components will not berepeated herein.

Mounting base 224 may be molded or formed to define the base portion 226a and a socket portion 224 a for receiving ball member 222 b of supportarm 222. The base portion 226 a may be molded over and at leastpartially around a metallic insert 226 b, such as described above withrespect to base portion 26 a. Base portion 226 a may be molded or formedwith a cavity 226 c and/or passageway for receiving the sensor or wire,or may be overmolded over and at least partially around the sensorand/or wire. The wire 234 comprises a flying lead or flexible lead thatextends from the base portion 226 a to the connector or terminals at thesupport arm 222, and includes sufficient slack or flexibility toaccommodate pivotal movement or articulation of the support arm relativeto the socket 224 a of mounting base 224. The other connector 230 a (atball member 222 a received in socket 220 (which may be formed at thecasing or at a toggle member or attachment or back plate of the mirror))may connect to a corresponding connector at a circuit board orelectrical element or the like at the mirror casing, such as tocircuitry on a circuit board at the reflective element or the like. Theelectrical element at or in the mirror casing may include controls ordisplay circuitry and elements that are associated with or incorporatedin a compass system and/or display system of the mirror assembly.

The accessory or sensor (or other electrical component or circuitry)thus may be positioned or located at or within the plastic moldedmounting base of the mirror assembly. The accessory thus is positionedgenerally along the longitudinal axis of the mounting arm, and generallybetween the ball member 222 b and the mounting base/mounting button atthe windshield when the mirror assembly is installed in a vehicle, andnot substantially above or below the mounting base (such as in a pod orgondola or module located above or below the mirror assembly) such as istypically done in known mirror assemblies. By positioning the accessorygenerally along the longitudinal axis of the support arm or generallyalong the z-axis (the axis along the vehicle and normal to the cross caror x-axis and the vertical or y-axis), the accessory is locatedgenerally between the windshield and the mirror casing and reflectiveelement when the mirror assembly is installed in the vehicle, and doesnot extend substantially above or below or to either side of the mirrorwhen the mirror assembly is installed in the vehicle. The mounting basethus may house or contain the accessory in a location that does notinterfere with the forward field of view of the driver of the vehicle.The mirror assembly of the present invention thus may provide a fixedsensor with double ball movement or articulation, and with reducedinterference with the forward field of view by the driver of thevehicle.

Optionally, and as discussed above, the electrical accessory orcircuitry housed or contained within the mounting base may comprise acompass sensor that is part of a compass system and/or display of themirror assembly and/or vehicle. Note that the magneto-responsive sensorused with the mirror assembly may comprise a magneto-responsive sensor,such as a magneto-resistive sensor such as the types disclosed in U.S.Pat. Nos. 5,255,442; 5,632,092; 5,802,727; 6,173,501; 6,427,349 and6,513,252 (which are hereby incorporated herein by reference), or amagneto-inductive sensor, such as described in U.S. Pat. No. 5,878,370(which is hereby incorporated herein by reference), or amagneto-impedance sensor, such as the types described in PCT PublicationNo. WO 2004/076971, published Sep. 10, 2004 (which is herebyincorporated herein by reference), or a Hall-effect sensor, such as thetypes described in U.S. Pat. Nos. 6,278,271; 5,942,895 and 6,184,679(which are hereby incorporated herein by reference). The sensorcircuitry and/or the circuitry in the mirror housing and associated withthe sensor may include processing circuitry. For example, a printedcircuit board may include processing circuitry which may includecompensation methods such as those described in U.S. Pat. Nos.4,546,551; 5,699,044; 4,953,305; 5,576,687; 5,632,092; 5,677,851;5,708,410; 5,737,226; 5,802,727; 5,878,370; 6,087,953; 6,173,508;6,222,460 and 6,642,851, which are all hereby incorporated herein byreference. The compass sensor may be incorporated in or associated witha compass system and/or display system for displaying a directionalheading of the vehicle to the driver, such as a compass system of thetypes described in U.S. Pat. Nos. 5,924,212; 4,862,594; 4,937,945;5,131,154; 5,255,442 and/or 5,632,092, and/or U.S. patent applicationSer. No. 10/456,599, filed Jun. 6, 2003, now U.S. Pat. No. 7,004,593;and/or Ser. No. 11/029,695, filed Jan. 5, 2005, now U.S. Pat. No.7,253,723, and/or PCT Application No. PCT/US2004/015424, filed May 18,2004, and/or U.S. provisional application Ser. No. 60/636,931, filedDec. 17, 2004, which are all hereby incorporated herein by reference.

Optionally, the sensor may comprise a two-axis sensor (comprising twomagneto-responsive sensor elements disposed orthogonally to each otherand disposed in the cavity 226 c generally parallel to the floor planeof the vehicle so as to be sensitive to the horizontal component of theEarth's magnetic field), or the sensor may comprise a three-axis sensor(comprising two magneto-responsive sensor elements disposed orthogonallyto each other and disposed in the cavity, and a third magneto-responsivesensor element at a right angle (approximately ninety degrees) to thetwo sensor elements and disposed in the cavity, so that the three-axissensor is sensitive to the horizontal component and to the verticalcomponent of the Earth's magnetic field), without affecting the scope ofthe present invention. The sensor may be arranged at a desired angle toprovide enhanced sensing in the horizontal directions when the mirrorassembly is installed in the vehicle. For example, aspects ofconstructions such as are disclosed in U.S. Pat. Nos. 6,140,933 and6,928,366, which are hereby incorporated herein by reference, may beutilized.

Optionally, an integrated automotive “compass-on-a-chip” may be disposedin the cavity of the mounting base and may comprise at least twomagneto-responsive sensor elements, associated A/D and D/A converters,associated microprocessor(s) and memory, associated signal processingand filtering, associated display driver and associated LIN/CAN BUSinterface and the like, all (or a sub-set thereof) created or disposedonto a silicon substrate (such as using CMOS technology) andconstituting an ASIC chip, which is small (preferably less thanapproximately a two square centimeter area, more preferably less thanapproximately a 1.5 square centimeter area, and most preferably lessthan approximately a one square centimeter area or thereabouts) andreadily packagable into the cavity.

Optionally, and preferably, such a compass-on-a-chip ASIC may alsoinclude the hardware and software required to receive an output from atemperature sensor (such as a thermocouple or thermostat that is locatedexternal the vehicle cabin in order to sense and monitor the temperatureexternal to the vehicle) and to convert this signal to a reading indegrees Fahrenheit or Celsius, and to provide this reading via anon-chip temperature display driver and/or via a BUS protocol or via anon-chip wireless transmitter or the like to a digital or other type oftemperature display so that the driver and/or occupants of the vehiclecan view the temperature being measured (such as the temperatureexternal the vehicle and/or the temperature within the vehicle cabin).Thus, for example, a monolithic compass/temp-on-a-chip ASIC may bedisposed in the likes of a mirror mount or within the mirrorhead/housing of an interior rearview mirror assembly, and it may provideboth the external temperature readout and a compass direction headingreadout to an information display at the mirror head/housing (orelsewhere in the vehicle, such as the instrument panel/cluster or at anoverhead console or accessory module or the like). Optionally, such achip or circuit board or circuitry may also or otherwise comprise ECdriver circuitry for controlling/driving an electro-optic orelectrochromic reflective element or cell, such as by utilizing aspectsof the EC driver-on-a-chip such as described in U.S. patent applicationSer. No. 11/201,661, filed Aug. 11, 2005, now U.S. Pat. No. 7,480,149,which is hereby incorporated herein by reference.

Optionally, and with reference to FIG. 8, a mirror assembly 210′ mayinclude a polymeric mounting base 224′ that includes a polymeric baseportion or mount portion 224 b′ that is attachable or connectable to apolymeric socket portion 225, with a cavity 227 defined at the junctionof the portions 225, 224 b′. The molded polymeric support arm 222′ mayinclude integrally molded wiring or electrical conductors 228′ thatextend between the ends of the ball members 222 a′, 222 b′, and that mayhave connectors 230 a, 230 b at the respective opposite ends of theconductors and ball members. The ball member 222 a′ includes theconnector 230 a′ extending therefrom, and is received within socket 220(which may be formed at the casing or at a toggle member or attachmentor back plate of the mirror) of mirror housing 218. The polymeric socketportion 225 may comprise a polymeric socket 224 a′ for receiving thepolymeric ball member 222 b′ therein and may have an opening or cavityor passageway 227 a from a base region of the socket 224 a′ to thecavity 227.

An electrical component or element, such as a printed circuit board 232′or other electrical element or circuitry or accessory or the like, maybe positioned within cavity 227 and may connect to the connector 230 b′(or to the ends or terminals of the conductors 228′) via a flying leador connecting wire or element 234′. The connecting wire 234′ may have aconnector 234 a′, such as a multi-pin plug or socket or the like, forconnecting to the corresponding connector 230 b′, such as acorresponding multi-pin plug or socket, at the ball member 222 b′. Thecircuit board 232′ may be received and retained within the cavity 227(such as by snapping into the cavity or otherwise inserting into thecavity), and may readily connect to the conductors 228′ of the supportarm 222′ when the support arm is attached to or received in the socket224 a′ (or may connect to the connector 230 b before being inserted intothe cavity). The circuit board and/or circuitry may include a compasssensor, such as described above, or other electrical elements orcircuitry or sensors, such as an antenna or the like, while the mirrorcasing may house or contain one or more electrical accessories, such aslights, display elements, sensors and the like, which are associatedwith or powered or controlled by the circuitry of the circuit board 232′via the electrical conductors 234′, 228′.

Socket portion 225 may attach to base portion or mount portion 224 b′ tosecure the socket portion to the mount portion and to retain the circuitboard within the cavity. The socket portion 225 and base portion 224 b′may snap together or may be otherwise secured together, such as viaultrasonic welding or the like, or by any suitable mechanical oradhesive attachment means. The polymeric base portion 224 b′ may includea metallic insert 226 b′ that may be insert molded within an overmoldedpolymeric or plastic portion 226 a′, such as in a similar manner asdescribed above. The mirror reflector or reflective element 214 andmirror housing or casing 218 and other elements or components of mirrorassembly 210′ may be substantially similar to the mirror assembly 210described above, such that a detailed discussion of the similar orcommon components of the mirror assemblies will not be repeated herein.

The mounting base thus may house or contain or capture an electricalcomponent or element or circuitry at a location that does not interferewith the forward field of view of the driver of the vehicle. Theelectrical component may be positioned within the mounting base andgenerally between the ball member 222 b′ (that is attached to themounting base) and the mounting button at the windshield when the mirrorassembly is installed in the vehicle. The electrical component and theelectrical connection between the electrical component and theelectrical conductors of the support arm are contained within themounting base and do not extend upward or downward or sideward so as tobe readily viewable by the driver of the vehicle when the mirrorassembly is installed in the vehicle.

Because the mounting base comprises a mount portion and a socketportion, the mirror assembly may be readily adapted for variousapplications or optional applications, such as for different vehicles orvehicle lines or platforms or for different options of a particularvehicle or vehicle line or the like. For example, the socket andmounting arm (and attachment plate or the like at the opposite or mirrorend of the mounting arm) may comprise standard or common components,while the mounting portion may be selected with the appropriate metallicinsert that matches or corresponds to the mounting button or the like ofthe particular vehicle in which the mirror assembly will be installed.For example, the mirror mounting button on the windshield of a MY05 VWvehicle is different than that on the windshield of a MY05 GeneralMotors vehicle, and thus this aspect of the current inventionfacilitates economic manufacture by the mirror manufacturer of standardinterior mirror assemblies but with only the mounting portion needed tobe customized to fit and attach to a particular automaker's design ofthe windshield mounting button. The appropriate mounting portion (withthe appropriate metal insert and mounting structure) thus may beselected and attached to the socket portion of a particular mirrorassembly, so that the mirror assembly is configured to be installed intoa particular vehicle or vehicle line or the like.

Optionally, the mounting portion may accommodate other accessories orcircuitry or the like as well, such as a rain sensor or imaging deviceor the like, and may electrically connect to the circuitry or connectorsof the socket portion. For example, the mounting portion may include arain sensor or the like and may position the rain sensor against thewindshield, such as described in U.S. Pat. Nos. 6,250,148; 6,341,523 and6,824,281, and in U.S. patent application Ser. No. 10/023,162, filedDec. 17, 2001, now U.S. Pat. No. 6,516,664; Ser. No. 10/348,514, filedJan. 21, 2003, now U.S. Pat. No. 6,968,736; Ser. No. 10/958,087, filedOct. 4, 2004, now U.S. Pat. No. 7,188,963; and/or Ser. No. 11/201,661,filed Aug. 11, 2005, now U.S. Pat. No. 7,480,149, which are all herebyincorporated herein by reference, or may include an imaging device, suchas an imaging array sensor for imaging systems of the types described inU.S. Pat. Nos. 6,757,109; 6,717,610; 6,396,397; 6,201,642; 6,353,392;6,313,454; 6,396,397; 5,550,677; 5,670,935; 5,796,094; 5,877,897;6,097,023 and/or 6,498,620, and/or U.S. patent application Ser. No.09/441,341, filed Nov. 16, 1999, now U.S. Pat. No. 7,339,149, and Ser.No. 10/427,051, filed Apr. 30, 2003, now U.S. Pat. No. 7,038,577, and/orU.S. provisional application Ser. No. 60/628,709, filed Nov. 17, 2004;Ser. No. 60/614,644, filed Sep. 30, 2004; Ser. No. 60/618,686, filedOct. 14, 2004; and/or Ser. No. 60/638,687, filed Dec. 23, 2004, whichare all hereby incorporated herein by reference. Optionally, themounting portion or mirror assembly may be at or in or associated withan accessory module or windshield electronics module or the like that islocated at or near the interior rearview mirror assembly, such as anaccessory module or windshield electronics module of the types describedin U.S. patent application Ser. No. 10/958,087, filed Oct. 4, 2004, nowU.S. Pat. No. 7,188,963; and Ser. No. 10/456,599, filed Jun. 6, 2003,now U.S. Pat. No. 7,004,593, and/or U.S. Pat. Nos. 6,824,281; 6,690,268;6,250,148; 6,341,523; 6,593,565; 6,428,172; 6,501,387; 6,329,925 and6,326,613, and/or in PCT Application No. PCT/US03/40611, filed Dec. 19,2003, and/or Ireland pat. applications, Ser. No. S2004/0614, filed Sep.15, 2004; Ser. No. S2004/0838, filed Dec. 14, 2004; and Ser. No.S2004/0840, filed Dec. 15, 2004, which are all hereby incorporatedherein by reference.

Optionally, and with reference to FIG. 9, the polymeric support arm 222″may include a multi-wire cable or harness 228″ insert molded therein.The wire or cable 228″ may comprise multiple electrical conductors orwires and may include flying leads 230 a″, 230 b″ or wires or cableextending from the opposite ends or ball members 222 a″, 222 b″ of thesupport arm 222″. The support arm 222″ may comprise a plastic molding,such as an acetal or engineering plastic resin or the like, and may bemolded over and around a portion of the wire or cable 228″. The leads230 a″, 230 b″ may include electrical connectors 231 a″, 231 b″ (such asmulti-pin connectors or the like, such as four pin or sixteen pin orother multi-pin plug and socket type connectors or the like) at the endsthereof for connection to the respective electrical connectors. Theplastic material may be molded around and over the electrical conductorsor the conductors may be fed or threaded through a pre-formed supportarm with a passageway formed therein. For example, the electricalconnector 231 a″ may connect to an electrical connector at a circuitboard in the mirror housing, while the connector 231 b″ may connect toan electrical connector at the mirror mount, such as to a vehicle wireharness or the like at or near the mirror mount. The leads andconnectors thus may be readily connected to the corresponding connectorsat the mirror mount and mirror casing, and the support arm may bereadily attached to or received in the sockets to pivotally andelectrically connect the mirror to the mirror mount. As shown in FIG. 9,one or both ball members may include an extension or knob 222 d at anend thereof. Such an extension is entirely optional, and may assist informing a stop or limit in the cavity included in the molded mirrormount or base to accommodate and allow movement of the flying lead wireharness.

For example, and with reference to FIG. 10, a support arm 322 of amirror assembly 310 may include a wire harness 328 integrally moldedinto the support arm 322, with leads 330 a, 330 b and connectors 331 a,331 b extending from the ball members 322 a, 322 b at each end of thesupport arm 322. The mirror assembly 310 may have a mirror housing orcasing 318 and reflective element 314 mounted at or attached to ballmember 322 a of support arm 322, and a mounting base 324 mounted at orattached to ball member 322 b of support arm 322.

The lead 330 a and connector 331 a may connect to a connector 336 at aprinted circuit board 338 within casing or housing 318, such as at aback plate or attachment plate 340 at the reflective element 314. Theback plate 340 may include the socket 320, which may be integrallyformed with the back plate 340 or may be attached to the back plate. Theback plate 340 and socket 320 may define a recess or cavity 342 forreceiving the lead 330 a as it extends from ball member 322 a, so thatsufficient clearance is provided to accommodate pivotal movement of thesupport arm relative to the socket 320 and back plate 340. The lead maybe positioned within the cavity 342 with sufficient slack or free playto allow for pivotal movement or articulation of the socket about theball member, without stressing the electrical conductors or wires.Although shown as a socket incorporated into or joined to the back plate(such as for a mirror assembly having an electro-optic reflectiveelement, such as an electrochromic reflective element or the like), thesocket for receiving ball member 322 a may be incorporated into orjoined to a toggle member (such as for a mirror assembly having aprismatic reflective element) or the mirror casing or the like, withoutaffecting the scope of the present invention.

Socket 324 a of mirror mount 324 may pivotally receive ball member 322 btherein, and may define a cavity 327 for receiving lead 330 b to providesufficient clearance to accommodate pivotal movement of the support armrelative to the socket 324 a. Connector 331 b may be positioned in theplastic mount portion 326 a of mirror mount 324, and may includemultiple pins or connecting elements that may be recessed within themount portion 326 a. As shown in FIG. 10, a wire harness 344 andconnector 344 a may be connected to the connector 331 b at the mirrormount 324, such as via a plug and socket connection or the like. Mirrormount may include a metallic insert 326 b, where the plastic portion 326a may be molded over and at least partially around the metallic insert326 b, such as in the manner discussed above. The metallic insert 326 bmay include the mounting structure for mounting or attaching the mirrorassembly to a mirror mounting button 346 or the like at a windshield 348of a vehicle, such as discussed above.

Optionally, and as shown in FIG. 11, a support arm 322′ of a mirrorassembly 310′ may include a wire harness 328′ that extends from theshaft 322 c′ of support arm before the ball member 322 a′ (andpreferably where the support arm is within the mirror casing 318 andthus concealed or not readily viewable), where the lead 330 a′ mayextend around the socket 320′ of back plate 340′ to connect to thecircuit board 338 via the connectors 331 a, 336. The other lead 330 b′may extend from the ball member 322 b′ into a cavity 327 of socket 324a′, such as in a similar manner as discussed above. The connectingelements of the connector or plug 331 b′ may be flush with or recessedin the exterior surface of the mirror mount, or may protrude from themirror mount 324′ (as shown in FIG. 11), without affecting the scope ofthe present invention. Mirror assembly 310′ may otherwise besubstantially similar to mirror assembly 310, described above, such thata detailed discussion of the mirror assemblies will not be repeatedherein. The similar or common components of the mirror assemblies areshown in FIGS. 10 and 11 with common reference numbers.

Optionally, the mounting base of the mirror assembly may be molded froma polymeric resin to incorporate a wire conduit or cover (or at least abase/bottom portion thereof), which may be positioned generally alongthe windshield and above the mounting base when the mounting base isattached to the mounting button on the windshield. The wire coverextends to the headliner of the vehicle, and conceals the vehicle orother accessory wire harness emanating from the roof portion so thatthis wire harness is not readily viewable to an occupant of the vehicleand is substantially contained within the wire cover or conduit. Themounting base may be formed or molded to have a portion of a wire cover(such as a conduiting member or wire passageway that extends about oneinch or thereabouts above the mounting base and that may receive thewire harness or lead therein), which may receive an end of a separatewire cover that contains and conceals the wire harness or lead betweenthe end of the partial cover and the headliner of the vehicle. The wirecover may insert into or receive the end of the partial cover (or mayotherwise connect or snap or join to the partial cover) extending fromthe mounting base, and may contain the wire harness or lead therein. Theappropriate length wire cover thus may be selected for the particularapplication, so as to provide the appropriate length cover depending onthe distance between the mirror mounting base and the headliner of aparticular vehicle model located proximate the junction of thewindshield with the vehicle roof. Optionally, the mirror mounting basemay include the full length wire cover or conduiting member extendingfrom the mounting base, and thus may be molded or formed/customized(such as by cutting the conduiting member to a desired or appropriatelength) for the particular vehicle model application.

For example, and with reference to FIG. 12, a mirror assembly 410includes a mounting base or mirror mount 424, a polymeric support arm422 and a mirror housing 418 and reflective element 414. The mirrorhousing 418, reflective element 414, back plate 440, socket 420 andsupport arm 422 may be substantially similar as the correspondingcomponents of mirror assembly 310′, discussed above, such that adetailed discussion of the mirror assemblies will not be repeatedherein. The similar or common components or elements between the mirrorassemblies 310′, 410 are shown in FIG. 12 with similar reference numbersto those of FIG. 11, but with 100 added to each reference number.

Mirror mount 424 includes a polymeric portion 426 a molded over a metalinsert 426 b, such as via similar molding processes discussed above. Themetal insert 426 b includes the mounting structure for mounting to orattaching to the mounting button 446 at the windshield 448. Similar tomirror mount 324, discussed above, mirror mount 424 includes a plasticsocket portion 424 a for receiving a ball member 422 b of support arm422, and defines a cavity 427 for receiving the lead 430 b of wires 428within the plastic or polymeric portion 426 a. Wire or conductingelements 430 b may terminate at a connector 431 b, which may bepositioned generally at an upper surface or region of the socket portionof the mirror mount. As can be seen in FIG. 12, the mirror mount 424 mayinclude a wire cover or conduiting member 450 that extends upward fromthe socket portion and generally along the windshield when the mirrorassembly is mounted at the windshield. In the illustrated embodiment,wire cover 450 is flexibly or movably attached to socket portion 424 avia a hinge portion 452, such as a living hinge molded with the coverand mirror mount, such that the cover 450 may move or flex or bend tofacilitate access to connector 431 b. The wire cover 450 at leastpartially defines a passageway 450 a along a body portion or upperportion 451 of the mirror mount when the wire cover 450 is pivoted alongthe body portion 451. The hinged cover 450 may extend substantiallyupward between the mirror mount and the headliner of the vehicle, or mayextend partially upward from the mirror mount and may receive or connectto a separate cover element or member 454, which may attach to cover 450and may extend along the windshield 448.

The mirror assembly thus may be installed by bringing the mounting base(already attached to the support arm and mirror) toward the mountingbutton at the windshield and attaching or mounting the mirror assemblyto the mounting button. The hinged cover 450 may be moved or bent orpivoted toward the support arm to facilitate access to the connector 431b, and the connector 444 a of wire harness 444 may be electricallyconnected to the connector 431 b of mounting base 424. The connector atthe end of the wire harness or lead (that extends from the headliner orfrom an overhead console of the vehicle) thus may be plugged into orotherwise connected to the connector at the mounting base (or at an endof a lead extending from the mounting base or from the support arm) whenthe mirror assembly is at or near or attached to or mounted on themounting button. After the connection is made, the hinged wire cover 450may be pivoted toward the windshield and may snap in place or may beotherwise secured in place along the windshield and/or along the bodyportion 451 of the mirror mount 424.

The wire cover thus may be adjustably joined to the body of the mountingbase, such as via a living hinge, which allows the wire cover to bend orfold to facilitate access to the connector at the mounting base so thatthe wire harness or lead may be electrically connected to the connector.When so connected, the wire cover may bend or flex or snap into theappropriate orientation or angle so that the wire cover extends upwardfrom the mounting base and generally along the windshield of thevehicle. Optionally, the wire harness may be routed or fed or positionedthrough and along the separate wire cover or conduiting member 454before the connection is made and the wire cover may connect to or jointo or snap to the partial conduiting member 450 extending from themounting base.

The plastic mounting base may be molded over the mounting structuralcomponent, such as a channel mount element or the like. The structuralcomponent is formed to mount to or attach to the mounting button at thewindshield. The mounting assembly may provide a breakaway mount, such asa mounting arrangement utilizing the principles described in U.S. Pat.No. 5,820,097, issued to Spooner; or U.S. Pat. No. 5,100,095, issued toHaan et al., the disclosures of which are hereby incorporated herein byreference. Typically, the mounting button comprises a metal button, suchas formed of a sintered or pressed steel or aluminum or a die-cast zincor the like, that is compatible with filed proven adhesives and thelike, such as silicone adhesive or modified epoxy or PVB (polyvinylbuteryl) or the like. The breakaway element is typically provided at themounting base or channel mount. It has been suggested to use engineeringplastics as a substitute for the metal mounting button; however, inorder to achieve the desired mechanical properties (including theability to reliably receive and hold a threaded fastener or screw tosecure the mounting base to the button), such metal-like engineeringplastics are sometimes used for the button, but the breakaway elementsremain at the channel mount or base.

Optionally, and with reference to FIG. 13, a mounting button 460 may beadhered or bonded to the windshield 448, and the mirror assembly(including the mounting base, support arm and mirror housing) may beattached to the mounting button to attach the mirror assembly to theinterior portion of the vehicle. As shown in FIG. 13, the mountingbutton 460 may be adhered or bonded to a blackout layer or frit layer462 at the interior surface 448 a of the windshield 448 via a suitableadhesive layer 464, such as a silicone adhesive, a PVB adhesive or anepoxy or the like. Although shown in FIG. 13 as having a generallyhorizontally oriented channel or receiving portion for slidablyreceiving the channel mount of the mounting base in a generallyhorizontal or side to side or lateral direction or orientation,typically, and preferably, the mounting button may have a generallyvertically oriented channel or receiving portion for slidably receivingthe channel mount in a generally vertical direction or orientation andalong the windshield. The mounting button may be implemented for eitherapplication, without affecting the scope of the present invention.

Mounting button/attachment member 460 may include a metal portion 460 a,which may be formed of a metal material, such as a die-cast zinc, asintered or processed steel or aluminum or the like, and a polymericmolded portion 460 b molded over and partially around the metal portion460 a. The metal portion 460 a may define a receiving portion 466 forreceiving the channel mount or mirror mounting base of the interiorrearview mirror assembly. The overmolded polymeric portion 460 b mayinclude tabs or elements 468 at the receiving portion to retain or holdthe mounting base at the receiving portion 466. The tabs or elements 468may provide a breakaway characteristic at the mounting button of themirror mounting arrangement, such that the mirror assembly may breakaway from the mounting button by breaking or bending or flexing of theelements 468 at the mounting button. The mounting button of the presentinvention thus provides the structural integrity of a metal mountingbutton, while also providing the breakaway elements at the mountingbutton.

The support assembly or mounting assembly of the mirror assembly of thepresent invention may be formed or molded together. Optionally, andpreferably, the conductors or wire harness or the like (preferablyincluding electrical connectors, such as plugs or sockets at endsthereof) may be obtained from an electrical supplier and placed in themold tool in an injection molding machine configured to mold the supportarm. The support arm may then be formed by injection of polymeric resin(such as acetal resin) into the injection molding tool over and aroundthe conductors or wire harness already placed therein, such that theflying leads and their terminal connectors extend from the respectiveends of the molded support arm when it is formed and removed from thetool (optionally, and less desirably, the conductors may be fed orthreaded through a passageway formed in and at least partially along analready-molded support arm, such as in a manner similar to thatdescribed in U.S. patent application Ser. No. 10/032,401, filed Dec. 20,2001, now U.S. Pat. No. 6,877,709, which is hereby incorporated hereinby reference).

The formed support arm (with the electrical conductors extendingtherefrom) may then be placed in a second mold, where the mirror mountor base portion may be molded over the ball member, and the back plateand socket may be molded over the ball member. Optionally, the connector(such as connector 331 b or 431 b, discussed above) may be molded inplace at the exterior portion of the mounting base (and optionally at orwithin a wire cover portion extending from the mounting base) so as tobe readily connected to the wire harness or the like at the mountingbase, while the other connector (such as connector 331 a or 431 a,discussed above) may be loose after the molding process so that theconnector may be connected to the circuit board or the like at thereflective element. The cavities (such as cavities 327 and 342,discussed above) at the mounting base and back plate provide space forthe flying leads (such as leads 330 b, 330 a, respectively) to providesufficient clearance for pivotal movement or articulation of the supportarm relative to the mounting base and/or back plate (or optionally atoggle member or the like depending on the particular application) ofthe mirror assembly.

The present invention thus provides a molded support arm and molded orovermolded mounting base. The molded support arm, the molded mountingbase and the molded back plate portion or toggle portion may all bemolded from the same polymeric resin material (such as acetal) or fromdifferent polymeric materials. For example, the support arm may bymolded from a high-stiffness engineering plastic resin, such as a glassor mineral filled nylon resin, and both the mounting base and the backplate/toggle can be molded from similar resinous material, such asacetal or such as a polyolefin resinous material, such as polypropyleneor the like. Alternately, and optionally, the support arm can be moldedfrom one polymer resin material, the mounting base from another polymerresin material, and the back plate/toggle from a third polymer resinmaterial. For example, a support arm can first be molded from fillednylon, and placed in an injection molding tool with twosections/cavities/regions. Then, a mounting base formed of acetal can beformed by injecting acetal resin into a first section/cavity/region ofthe tool at one end of the support arm, and a back plate/toggle can begenerally simultaneously formed at the other end of the support arm,such as by injecting a filled polyolefin or an ABS resin into a secondmold section or cavity or region. Such dual injection molding orovermolding can be used to customize the individual appearance (such ascolor or texture) and/or performance (such as ball/socket torque) of thesupport arm, the mounting base and the back plate/toggle portion. Also,differential molding packing pressures and/or tool surfaces/texturingand/or ball/socket sizing can be used to achieve a far higher torque forthe ball joint formed via overmolding of the mounting base to the ballat one end of the support arm than is achieved for the ball/socket jointat the other end via overmolding of the back plate/toggle thereat. Themounting base may include or house or contain an electrical accessory orsensor or circuitry or circuit board therein, and the support member mayhave electrical conductors insert molded therein. The electricalconductors may include electrical connectors at respective ends, and mayreadily connect to an electrical accessory or circuitry or circuit boardat the mirror and to an electrical accessory or circuitry or circuitboard or wire harness at the mounting base.

The electrical accessory or sensor or circuitry or circuit board at orin the mounting base may be positioned within the mounting base andgenerally between the windshield and the ball member of the support armthat is attached to the mounting base. The electrical accessory orcomponent or element thus is at a location that is not readily viewableby a driver of the vehicle when the mirror assembly is installed in thevehicle. The mounting base and/or the back plate of the reflectiveelement may be molded over the ball members of the support arm and maycontain the leads and/or connectors of the support arm therein.

Optionally, and with reference to FIGS. 14 and 15, a support arm 422′may include a substantially rigid stiffening element or insert element423 insert molded within the support arm to provide additional strengthand rigidity to the support arm. The stiffening element 423 may comprisea hollow tube or conduit, such as a metal tube or conduit, such asaluminum or zinc or magnesium or copper or brass or steel or an Inconelor any alloy of these or any other metal or the like, or such as aceramic tube or conduit, or such as a plastic or polymeric tube orconduit (comprising a plastic material (such as an engineering plasticor polymeric material or a highly glass or mineral filled nylon or thelike) that is stiffer or more rigid and stronger than the plasticmaterial of the overmolded support arm), or the like. Many suchengineering polymeric resins, often due to the high filler content, donot provide an aesthetically attractive/customizable Class A outwardappearance. Thus, a central core engineering plastic (such as reinforcednylon or the like) rigid stiffening arm or insert element can be moldedor formed and can be overmolded with a less rigid/less structurallystrong resinous material, such as an unfilled polymeric resin material,such as a polypropylene or a polyethylene or the like, which provides amore desired or aesthetic appearance or texture or outer surfacecharacteristic or finish (such as a Class A finish) or the like. Thus, astructural core (that may be metal) that provides structural rigidityand/or vibration reduction/dampening is sheathed/encased in an outerplastic molding that imparts the desired texture/color/appearance to thepart. The wall thickness of such a stiffening tube or conduit (orcross-sectional diameter if a solid stiffening element) may be chosen tobe whatever dimension is desired to achieve the desired enhancement ofrigidity of the support arm, and the overall dimensions may be chosen tooptimize rigidity enhancement while minimizing added weight.

The electrical wire harness 428 may be routed through the stiffeningtube 423 and may extend through the ball members 422 a′, 422 b′ forconnection to the connectors 436, 444 a at the circuit board 438 and themounting base or mirror mount 424′, respectively. In the illustratedembodiment, the insert element or stiffening tube terminates inward fromthe ends of the support arm, such that portions of the wire harness areinsert molded within the support arm material (though, alternately, ahollow channel or passageway or conduit could be included in the moldingat one or both ends of the support arm to provide a wire passageway forthe cable leading into/out of the central/core stiffening tube orelement). The wire harness 428 may include plug or socket connectors 431a, 431 b for electrically connecting the wire harness to the connectors436, 444 a at the circuit board 438 at the mirror head and the vehiclewire harness 444 at the mirror base, respectively. The mountingarrangement and mirror assembly 410′ may otherwise be substantiallysimilar to the mounting arrangement and mirror assembly 410 of FIG. 12,discussed above, such that a detailed discussion of the mountingarrangements and mirror assemblies will not be repeated herein. Thecommon or similar components are shown in FIG. 15 with the samereference numbers as used in FIG. 12.

The insert element or stiffening element 423 may extend substantiallythe length of the support arm (and/or may terminate inward of the endsof the support arm as shown in FIGS. 14 and 15) or may be sized so thatthe stiffening element protrudes partially from one or both ends of thesupport arm, without affecting the scope of the present invention.Optionally, the stiffening element or tube may terminate near the endsor outer surface of the ball members but within the ball members. Thearm material may be molded over the tube and over the ends of the tube.The thin wall portion of the ball members at the ends of the tube may bepunctured or punched or broken through after the arm is molded and curedto create the passageway through the arm. The thin walls at the ends ofthe tube may be punched through or broken after the toggle and/ormounting base are molded over the ball members, so that material fromthe subsequent molding processes will not infiltrate the tube passagewayduring the subsequent molding of the toggle and/or mounting base.

Optionally, the wire harness 428 may pass through the stiffening elementand may extend from the opposite ends of the ball members of the supportarm, or may extend through different portions of the ball members or mayexit the support arm at or along the arm portion 422 c′ of the supportarm (such as shown in FIG. 12), or the like, without affecting the scopeof the present invention. Optionally, the stiffening element need not behollow, and may comprise a solid stiffening element to providereinforcement and/or stiffening characteristics to the support arm(which may or may not have a wire or wire harness routed or insertmolded therethrough). Although shown extending along a substantiallystraight support arm, it is envisioned that the support arm and/or theinsert element or stiffening element may comprise a non-straightelement, such as a curved support arm and/or a curved insert element,without affecting the scope of the present invention.

Optionally, the stiffening element may include vibration reducing ordampening characteristics, such as structural characteristics orproperties or the like, that function to reduce/dampen the vibration ofthe support arm and mirror head. For example, the stiffening element mayinclude materials or structures, such as soft materials and/or aeratedmaterials and/or foamed materials or the like, that are embedded inand/or integrally molded within the plastic support arm. Optionally,such as for applications where reduced vibration is a dominant desire,the materials used and/or the designs employed for the insert elementmay not necessarily add stiffening and/or rigidity inducing/enhancingcharacteristics, but may improve vibration functionality or performancevia vibration reducing/dampening characteristics and/or materials and/orfeatures. The insert element thus may improve vibration performance ofthe mirror via a vibration dampening functionality, which may includethe use of materials and/or structure embedded and/or integrally moldedwithin the plastic or polymeric support arm. For example, the insertelement may include characteristics or features, such as a non-straightshape or form, such as a serpentine shape or form, or a multi-vane shapeor form or the like, in order to reduce, dampen, dissipate and/orameliorate vibration of the mirror. Also, or alternately, the insertelement or vibration functionality may include the use of soft materialsand/or foamed materials and/or aerated materials within the support armand/or other such vibration reducing/damping materials and/or featuresand/or characteristics such as are known in the vibrationreducing/damping arts.

Thus, the stiffening element and wire harness subassembly may bepre-formed by a wire harness manufacturer. For example, the wire harnessmanufacturer may thread the wires or conducting elements through thehollow stiffening tube, and then attach the connector or connectors toone or both of the ends of the wires. The wires and connectors, with thestiffening tube around at least a portion of the wires, may then beshipped to the support arm molding facility or location or the like forforming the support arm over and around the stiffening element and aportion of the wires. For example, the stiffening element may be placedin a support arm mold, and the wires protruding from either end of thestiffening element may be placed or routed to the appropriate locationsin the mold cavity, and the support arm material (such as an acetal orengineering plastic resin or the like) may be molded over the stiffeningelement and portion of wires within the cavity to form the support armabout the stiffening element. The support arm (with the insert elementor stiffening element insert molded therewithin) may then be attached tothe mounting base and mirror head socket, and the wire may beelectrically connected to the connector at the printed circuit board ofthe mirror head. Optionally, and as described above, the molded arms maybe loaded into a mold tool and the mirror mount material and togglematerial may be injected into the respective tool cavities to form themirror mount and toggle material around or partially around therespective ball members of the support arm. Optionally, multiple moldedarms may be picked up and placed or loaded (such as by a robotic deviceor automated device the like) into multi-cavity mold tools to formmultiple mounting assemblies via a substantially automated moldingprocess. The assembled mirror assembly may be shipped to a vehicleassembly plant, where the mirror assembly may be mounted or attached toa mounting button at the vehicle windshield (or to any other mountingstructure within the vehicle), and the vehicle wiring harness may beelectrically connected to the connector at the mounting base of themirror assembly to electrically connect the vehicle wiring to the mirrorhead.

Optionally, and with reference to FIG. 16, the mirror housing 418 andreflective element 414 of an interior rearview mirror assembly 410″ maybe mounted to a mounting base or mirror mount 424″ via the support arm422′. The mirror housing 418, reflective element 414, back plate 440,socket 420 and support arm 422′ may be substantially similar as thecorresponding components of mirror assemblies 410, 410′, discussedabove, such that a detailed discussion of the mirror assemblies will notbe repeated herein. The similar or common components or elements betweenthe mirror assemblies 410, 410′ and 410″ are shown in FIG. 16 withsimilar reference numbers to those of FIGS. 12 and 15.

The polymeric portion 426 a″ of mirror mount 424″ includes the socketportion 424 a″ and a shield portion or wall portion or pocket portion424 b″ that extends upward from socket portion 424 a″ and generallyalong the interior surface 448 a of the windshield 448. Shield portion424 b″ provides opposite sidewalls 425 a″ and a cabin side wall 425 b″and a windshield side wall 425 c″ extending upward from socket portion424 a″ to define a cavity or receiving pocket into which the vehiclewire harness 444 and connector 444 a can be inserted to connect to thecorresponding connector 431 b of mirror wire harness 428. In theillustrated embodiment, the connector or plug 431 b (or socket) ofmirror wire harness 428 is secured or retained or positioned at thesocket portion 424 a″ of mounting base 424″ and is accessible at a loweror bottom portion of the cavity defined by the walls 425 a″, 425 b″, 425c″ of shield portion 424 b″, so that the connector or socket 444 a (orplug) of vehicle wire harness 444 may be readily connected or pluggedinto the connector 431 b of vehicle wire harness 428, such as after themirror assembly 410″ is mounted to the mounting button 446 at thewindshield 448.

Shield portion 424 b″ includes opposite side walls 425 a″ that extendupward along the sides of the mirror mount and limit or substantiallypreclude a driver or occupant of the vehicle or a person outside of thevehicle from viewing the vehicle wire harness and the connectors orplug/socket or joint of the wire harnesses from either side of therearview mirror assembly 410″ when the mirror assembly is installed inthe vehicle. Likewise, the shield portion 424 b″ includes a rear orinterior or cabin side wall portion 425 b″ that extends upward from thesocket portion 424 a″ and limits or substantially precludes the driveror occupant of the vehicle from viewing the vehicle wire harness and theconnectors or plug/socket or joint of the wire harnesses from within thecabin of the vehicle. Also, the shield portion 424 b″ includes a frontor windshield side wall portion 425 c″ that extends upward and generallyalong the windshield 448 to limit or substantially preclude a personoutside of the vehicle from viewing the vehicle wire harness and theconnectors or plug/socket or joint of the wire harnesses from outside ofthe vehicle cabin and through the vehicle windshield. The sidewalls 425a″, rear wall portion 425 b″ and front wall portion 425 c″ may beunitarily formed together and function to define a receiving cavity orpocket for the vehicle wire harness and connector to be inserted into orreceived into for connection to the connector of the mirror wireharness, such as after the mirror assembly is mounted to the mountingbutton at the vehicle windshield.

The shield portion 424 b″ thus at least partially defines asubstantially encased or enclosed cavity and/or passageway along thewindshield and at least partially toward the headliner of the vehicle.Optionally, a separate cover element or member 454″ may substantiallyencase the vehicle wire harness 444 between the shield portion 424 b″and the vehicle headliner, and may attach to an upper portion of shieldportion 424 b″. The cover member 454″ thus may extend along thewindshield 448 and substantially encase and conceal the vehicle wireharness 444 between the mount 424″ and the headliner so that the wireharness 444 is not readily viewable by a driver or occupant of thevehicle. The cover member 454″ may attach to the upper end of the shieldportion 424 b″, such as via a snap type connection or the like, so as tobe substantially retained to the shield portion 424 b″ of the mirrormount or base 424″.

The mirror assembly thus may be installed by bringing the mounting base(already attached to the support arm and mirror) toward the mountingbutton at the windshield and attaching or mounting the mirror assemblyto the mounting button. The vehicle connector 444 a of wire harness 444may be electrically connected to the connector 431 b within the pocketor cavity of the shield portion 424 b″ of mounting base 424″. Theconnector at the end of the wire harness or lead (that extends from theheadliner or from an overhead console of the vehicle) thus may beplugged into or otherwise connected to the connector at the mountingbase (or at an end of a lead extending from the mounting base or fromthe support arm) when the mirror assembly is at or near or attached toor mounted on the mounting button. Optionally, the wire harness 444 maybe routed or fed or positioned through and along the separate wire coveror conduiting member 454″ before the connection is made and the wirecover may connect to or join to or snap to the shield portion 424 b″ atan upper end of the mounting base.

Thus, and in accordance with the present invention, the plug connectorat the end of a wire harness coming from the upper windshieldarea/headliner/roof of the vehicle may be received by, nested in and/orenveloped by the upper portion of the mirror mount of the interiorrearview mirror assembly, and the presence of the plug connector of thewire harness to the socket within the mirror mount (or vice versa) ishidden from view from the front of the vehicle through the windshield,and hidden from view by an occupant within the vehicle cabin) by theplastic shielding portion/wall of the mirror mount. Note that aspreviously described, a portion of the mirror mount or shield or wallmay be hinged and/or detachable/replaceable, such as a trap door orremovable cover or the like, to facilitate or ease making theplug/socket connection.

Optionally, and preferably, an end portion of a wire cover canmechanically attach, such as by a snap or snug connection, to the upperportion of the mirror mount, so that essentially the presence of thewire harness and its connection to the mirror assembly is hidden fromdirect view. Many vehicle connector wire harnesses terminate in thelikes of a multi-pin connector having, for example, eight or ten or evensixteen parallel pins/connectors (such as about ½ inch to an inch ormore in length). The upper portion of the mirror mount thus may beconfigured so that is wider (wider transverse across the vehicle) thanthe lower portion so as to accommodate such a wide connector. Such aconfiguration places the wider/waisted upper portion of the mirror mounttypically above the ball joint at the mirror mount when the mirrorassembly is normally mounted in the vehicle, without the lower portionof the mirror mount being required or desired to be similarly broaderdimension. This places the wider connection portion substantially hiddenand substantially behind the mirror casing when viewed by the driver,and at an upper portion not likely to interfere with the field of viewthrough the windshield below the mirror button location.

Optionally, and with reference to FIGS. 29-31, an interior rearviewmirror assembly 470 may be pivotally attached to a mounting arrangement472 at an interior portion of a vehicle, such as at an interior surfaceof a vehicle windshield. The interior rearview mirror is pivotallyattached (such as by using a two ball pivot attachment or a one ballpivot attachment such as are known in the interior rearview mirror arts)to a mounting arm 474, which is pivotally attached to a base portion orchannel mount portion 476 of the mounting arrangement 472 (exemplaryembodiments of such one or two ball mounting arrangements are discussedabove and are shown in U.S. Pat. Nos. 4,936,533; 5,820,097; 5,100,095;5,555,136; 5,582,383; 5,680,263; 5,984,482; 6,227,675; 6,229,319 and6,315,421, the disclosures of which are hereby incorporated herein byreference).

Base portion or mount 476 may receive or attach to a mounting button 478or the like at the windshield surface, and includes a channel or cavityor receiving portion 476 a that is open at an upper end of the baseportion. As shown in FIG. 30, a circuit element 480, such as a printedcircuit board or a flexible circuit board or electronic chip or othercircuitry or circuit element, may be received within the channel orreceiving portion 476 a, and may be electrically or conductivelyconnected to a plug or connector 482. The plug 482 is at least partiallyreceived in channel or cavity or receiving portion 476 a and protrudesgenerally upwardly and along the windshield from the base portion ormount 476. Although shown and described as a male connector or plug, theconnector may alternatively comprise a female connector or socket orother electrical connector, without affecting the scope of the presentinvention. A wire cover 484 attaches to the upper end of theaccessorized base portion or mount 476 and extends along the windshieldbetween the base portion and the vehicle headliner. The wire cover 484includes an electrical wire or cable that routes through and along thewire cover between the headliner and the base portion. Wire cover 484includes a connector or socket (or other suitable male or femaleconnector for connecting to the connector at the base portion) at itslower end for connecting (and preferably snap-connecting) to theconnector or plug 482 at the upper end of the accessorized base portionor mount 476.

The mounting arrangement 472 thus may provide a mounting location foraccessory circuitry, such as a stand-alone compass circuit or system,preferably including a “compass-on-a-chip” as described above, or thelike, at the windshield and generally behind the mirror and thussubstantially concealed from view by the driver of the vehicle.Preferably, the mounting arrangement is configured so that at least twoof the magneto-responsive compass sensors of the compass circuit arearranged generally horizontal and generally parallel to the ground whenthe compass circuitry is mounted within the mounting arrangement of thepresent invention and the mounting arrangement is mounted within thevehicle. Optionally, the circuitry element or circuit board or chip atthe base portion may be electrically connected to circuitry within themirror casing, such as via wiring or the like routed through themounting arm, such as in the manners described above.

Prior art interior rearview mirror assemblies (such as the typesdescribed in U.S. Pat. Nos. 5,576,687 and 6,877,888, which are herebyincorporated herein by reference) have included the use of pods thattypically and preferably can detach from the mirror mount, typically bysnapping onto where the ball exits the mount. While such arrangementshave good utility, they tend to be styling obvious to the driver of thevehicle and may be bulky and large.

Optionally, the circuitry element or circuit board or chip may not beelectrically connected to accessories or circuitry of the mirror, andmay be separate from the mirror accessories or electrical content. Forexample, the mirror may comprise a prismatic reflective element ormirror (such as shown in FIG. 29) and may comprise a base level mirror,with no electronic accessories or circuitry within the mirror casing.The mounting arrangement of the present invention may receive anappropriate circuit element or circuit board or chip to provide thedesired electronic content or feature at or near the mirror assembly.For example, the circuit element may comprise compass circuitry(including, for example, the appropriate magneto-responsive sensorelements, microprocessor, LIN/CAN communication circuitry and the like),thereby providing a stand-alone compass system without requiring anupgrade to a mirror assembly with the desired electronic content. Thedesired electrical feature (such as a compass system or compass sensorand circuitry) may be provided with the circuit element or chip orcircuit board, and an associated display may be provided elsewhere inthe vehicle and remote from the mirror assembly. For example, compasscircuitry can be included in the mirror mount base portion that providesa compass directional heading signal, preferably over a LIN or CAN busconnection or the like, to a compass display located remote and awayfrom the mirror assembly, such as in the instrument panel or an overheadconsole or the like.

The desired electronic feature thus may be selected and readilyinstalled in the vehicle with little or no changes required to themirror assembly. The desired electrical content may be readily installedin the vehicle at the assembly plant without affecting the mirrorcontent or other accessory content of the mirror or accessory module orvehicle. The accessorized or accessorizable mirror mount is thusconstructed with a cavity or internal structure or receiving portion sothat an accessory, such as an electronic circuit board or an electronicmodule or the like, can be included therein, with ease of incorporationand assembly at the mirror manufacturer or vehicle assembly line, butwith the incorporation and presence of the accessory being largelyunnoticed or unnoted by the owner of the vehicle. The mirror mount thusis not being unduly enlarged so as to be styling objectionable and/or soas to unduly impede the forward field of view of the driver through thewindshield. In this regard, incorporation of the internal structureand/or cavity in the portion of the mirror mount that is above thebutton on the windshield when the mirror mounts thereto is preferredbecause the central upper windshield region between the button and wherethe windshield meets the head liner or roof region is largely unused bythe driver for the forward driving task.

The supplier of the mirror mount thus may manufacture a mount with amechanical attachment portion adapted for attaching the mirror mount tothe vehicle. The mount may include electronic circuitry or a similaraccessory (and may be capped), or may be left unoccupied and capped(largely for cosmetic effect or for later incorporation of anaccessory), depending on the particular application and desiredelectrical content or accessory of the mount and/or mirror system(optionally, the same cap provided with an unoccupied mount may bereplaced at the mount after an accessory is incorporated into the mountto conceal/hide the presence of the accessory within the mirror mount,or the accessory itself, when plugged or inserted into the rest of themount, may complete the external styling of the mirror mount, such asshown at 484′ in FIG. 31). For example, the mount may be provided with aremovable “dummy” cap that may be removed by the vehicle manufacturer(or by the mirror manufacturer) to allow the desired electrical contentto be added to the mount, if desired.

The mount thus may be provided as a standardized item (and by a separatemanufacturer or manufacturing line from the manufacturer ormanufacturing line of the complete mirror assembly itself), and may thenbe customized or accessorized for the particular vehicle or particularapplication of the mount and mirror assembly. The mirror manufacturer orvehicle manufacturer may then add in the desired or standard accessoryor accessories or circuitry (such as, for example, compass circuitry orthe like) to the standard mount. The mount thus may be sold or suppliedor provided as a separate unit, and not part of the mirror assembly, andmay be populated (such as by adding/inserting/attaching the desiredaccessory or circuitry) by the mount provider or by another manufactureror competitor (such as the vehicle manufacturer or mirror manufactureror the like). Although shown and described as providing a cavity forinserting an accessory at an upper portion of the accessorized mirrormount, it is envisioned that one or more cavities or caps or connectorsmay be provided at the side or sides of the mount or at the bottom orlower portion of the mount to allow for other accessories or the like atthe mirror mount (such as accessories or components utilizing aspects ofthe types described in U.S. Pat. Nos. 6,902,284; 6,824,281 and6,690,268, which are hereby incorporated herein by reference).

Thus, the installation of the mirror assembly and assembly of the wirecover to the base portion may be readily accomplished by an operator atthe vehicle assembly plant, in order to provide the desired orappropriate electrical feature at the mirror assembly or remote from themirror assembly. For example, the base portion (with mounting arm andmirror assembly attached thereto) may be slid onto and secured to themounting button at the windshield, and the appropriate chip or circuitboard and associated connector may be readily inserted into and secured(such as via a snap fit connection) at the upper end of the baseportion. The wire cover then may be snapped to the connector to completethe electrical and mechanical connections.

Optionally, and as shown in FIG. 31, the wire or cable 485 of the wirecover 484′ may include an electrical connector or plug or socket 485 aat its upper end for electrical connection to the vehicle wire harnessat the headliner of the vehicle. Optionally, and as also shown in FIG.31, the connector or plug 482′ may have the circuit board or chipattached thereto and/or the wire cover 484′ may have the circuit boardor chip retained thereto or therein, whereby the wire cover may bereadily attached to the upper end of the base portion to complete theinstallation of the circuit board or chip at the windshield. The wirecover thus may include the circuitry and wiring and may be readilyattached or snapped or clipped onto the upper end of the base portion toprovide the desired electrical content at the mounting base of themirror assembly. The present invention thus provides an accessorizedmirror mount that may include at least one electrical accessoryintegrated or included in or includable in or within its structure.

Optionally, and with reference to FIG. 17, an interior rearview mirrorassembly 510 may include a support assembly 512 that supports or mountsa mirror housing or casing 518 and reflective element assembly (notshown in FIG. 17) at an interior portion of a vehicle, such as at amounting button 520 at a windshield 511 of a vehicle. The supportassembly 512 includes a support arm 522 that is pivotally engaged with amounting base 524 (which is attachable to the mounting button 520 at thewindshield) at one end 522 a and with the mirror casing 518 at the otherend 522 b. As shown in FIG. 17, the support arm 522 comprises agenerally hollow tube with open ends 522 a, 522 b, which partiallyreceive a curved or rounded or partially spherical portion 524 a, 518 aof the respective mounting base 524 or mirror casing 518. The ends 522a, 522 b may have curved engaging surfaces for substantially uniformlyengaging the curved or rounded or partially spherical portions 524 a,518 a of the mounting base 524 and mirror casing 518 to facilitatesubstantially smooth pivotal movement of the mirror casing 518 relativeto end 522 b and of the end 522 a relative to the mounting base 524. Anelectrical wire or wiring harness 526 may extend from the mirror head(such as from a circuit board or circuitry at the mirror head and withinthe mirror casing), through the support arm 522 and further through themounting base 524 and out of the mounting base for electrical connectionto a vehicle power source or wiring harness, such as at the headliner oran overhead console of the vehicle.

As can be seen in FIG. 17, the support assembly 512 includes a biasingmember or spring 528 that extends along support arm 522 and protrudesfrom the ends 522 a, 522 b of support arm 522 and connects to respectivemounts or attachment members 524 b, 518 b at the mounting base 524 andcasing 518. The biasing member 528 thus biases the casing 518 toward themounting base 524, and thus biases both the casing 518 and mounting basetoward and into engagement with the respective ends 522 b, 522 a of thesupport arm 522. The biasing member 528 may include hooks or engagingportions 528 a, 528 b at opposite ends for connecting to or engagingwith the members 524 b, 518 b. The members 524 b, 418 b may comprisemetal or plastic pins or elements that extend from one or more walls ofthe mounting base 524 and casing 518, and may be insert molded thereinor integrally molded as part of the mounting base and/or casing, or maybe positioned within the mounting base and/or casing after thebase/casing is formed, without affecting the scope of the presentinvention.

The biasing member may provide a desired biasing force or pulling forceto provide the desired frictional engagement of the support arm endswith the respective mounting base or mirror casing. Optionally, thesurface finish of the ends 522 a, 522 b and/or of the curved/roundedportions 524 a, 518 a may be selected to provide the desired frictionalresistance to movement of the support arm 522 relative to the mountingbase 524 and/or mirror casing 518. The surface finish may be differentat one joint as compared to the other joint to provide the desiredresistance at each joint (for example, the frictional resistance may bereduced at the mirror casing joint as compared to the frictionalresistance at the mounting base joint). Optionally, the diameter orradius of curvature of one or both of the rounded portions 524 a, 518 amay be selected or adjusted (and the curved engaging surface at one orboth ends 522 a, 522 b of the support arm may be correspondinglyselected or adjusted) to provide the desired surface engagement andclamping force at the respective joints (and thus providing a selectedor desired effective diameter of the rounded portion of the respectivejoint or joints of the support assembly).

The support arm 522 may comprise a metallic material or a polymeric orplastic material, without affecting the scope of the present invention.Also, the mounting base 524 may comprise a metallic material or apolymeric or plastic material, while the casing may comprise a metallicmaterial or a polymeric material, without affecting the scope of thepresent invention. Although shown as being part of the casing in FIG.17, the rounded portion 518 a may be part of an attachment plate thatattaches to the reflective element or to a toggle member or assembly(for prismatic reflective element applications) or may be otherwiseincorporated into and protruding from the mirror casing, withoutaffecting the scope of the present invention. Optionally, one or both ofthe rounded portions 524 a, 518 a may include a stop or tab portion(such as shown at 518 c in FIG. 17 or such as other protrusions or tabsthat may extend from a portion of the rounded portions, such as at thetab 524 c shown in phantom in FIG. 17) for engaging the sidewalls of thesupport arm to limit pivotal movement of the support arm relative to therespective rounded portion or ball portion of the support assembly.

The support assembly of the present invention thus provides a robust andstable support arm and pivot joints for the support arm, and thusprovides an enhanced support assembly for pivotally supporting themirror head or casing relative to the mounting base of the mirrorassembly. The support arm may comprise a large diameter support memberand may be substantially hollow to provide enhanced access to the wiringextending through the support arm. The support arm may be substantiallyhollow and tubular or may provide a narrower passageway therethrough(for receiving the biasing member and wiring therethrough), and mayprovide an insert member or conduit (such as described above withrespect to FIGS. 14 and 15) therethrough for receiving the biasingmember and wiring, without affecting the scope of the present invention.

Although shown as having partial spherical or rounded or curved portionsat the mounting base and at the casing (or attachment plate or thelike), the support arm may include one or more rounded or partiallyspherical ends that are formed to be partially received within one ormore correspondingly curved or formed partial sockets at the mountingbase and/or mirror casing (or attachment plate or the like). Forexample, and with reference to FIG. 18, an interior rearview mirrorassembly 510′ may include a support assembly 512′ that supports ormounts a mirror housing or casing 518′ and reflective element assembly(not shown in FIG. 18) at an interior portion of a vehicle, such as at amounting button 520 at a windshield 511 of a vehicle. The supportassembly 512′ includes a support arm 522′ that is pivotally engaged witha mounting base 524′ (which is attachable to the mounting button 520 atthe windshield) at one end 522 a′ and with the mirror casing 518′ at theother end 522 b′. Similar to support arm 522, support arm 522′ comprisesa generally hollow tube with a generally open end 522 a′ that partiallyreceives the curved or rounded or partially spherical portion 524 a′ ofthe mounting base 524′ to pivotally attach the support arm to themounting base. The opposite end 522 b′ of support arm 522′ comprises apartially curved or rounded or partially spherical end, which ispartially received within a curved or partial socket 518 a′ at themirror casing 518′.

The support assembly 512′ includes a biasing member or spring 528′ thatextends along support arm 522′ and protrudes from the ends 522 a′, 522b′ of support arm 522′ and connects to respective mounts or attachmentmembers 524 b′, 518 b′ at the mounting base 524′ and mirror casing 518′.The attachment member 524 b′ may be formed as a lip or hook in themounting base 524′ such that the hook end 528 a′ of biasing member 528′may readily hook over the attachment member 524 b′ to attach the biasingmember to the mounting base 524′. Likewise, the attachment member 518 b′may be formed or positioned at the mirror casing 518′ such that the hookend 528 b′ of the biasing member 528′ may readily hook over or partiallyaround the attachment member 518 b′ to attach the biasing member to themirror casing (or to an attachment plate or the like at or in the mirrorcasing). The support assembly 512′ may otherwise be substantiallysimilar to the support assembly 512, discussed above, such that adetailed discussion of the support assemblies will not be repeatedherein. Although not shown in FIG. 18, the mirror assembly 510′ mayinclude a wiring harness or the like that may be routed from the mirrorhead (such as from a circuit board or circuitry at or in the mirror heador casing), through the support arm and further through the mountingbase and up toward and into electrical connection with a vehicle wiringharness, such as at the headliner of the vehicle or at an overheadconsole of the vehicle or the like. Other variations to the support armand mounting base and casing (such as providing different radii ofcurvature and different partial spherical portions and partial socketsat either the support arm or the mounting base or mirror casing) may beimplemented without affecting the scope of the present invention.

Optionally, and with reference to FIGS. 19-21, a support assembly 512″,which supports or mounts a mirror housing or casing and reflectiveelement assembly (not shown in FIGS. 19-21) at an interior portion of avehicle, includes a support arm 522″ that is pivotally engaged with amounting base 524″ at one end 522 a″ and with an attachment plate 518″at the other end 522 b″. Similar to support arm 522, discussed above,support arm 522″ comprises a generally hollow tube with a generally openend 522 a″ that partially receives the curved or rounded or partiallyspherical portion 524 a″ of the mounting base 524″ to pivotally attachthe support arm to the mounting base, and the opposite generally openend 522 b″ of support arm 522″ is configured to partially receive apartially curved or rounded or partially spherical portion 518 a″ at theattachment plate 518″. The support assembly 512″ includes a biasingmember or spring (not shown in FIGS. 19-21) that extends along supportarm 522″ and protrudes from the ends 522 a″, 522 b″ of support arm 522″and connects to respective mounts or attachment members 524 b″, 518 b″(FIG. 21) at the mounting base 524″ and attachment plate 518″. Theattachment plate 518″ includes a generally planar or plate portion 518c″ that is attachable to the mirror reflective element (such as via anadhesive or tape or the like) or to another portion of the mirror casingor mirror head, while the mounting base is attachable to an interiorportion of the vehicle, such as to a mounting button or the like at theinterior surface of the vehicle windshield or the like. The supportassembly 512″ may otherwise be substantially similar to the supportassemblies 512 and/or 512′, discussed above, such that a detaileddiscussion of the support assemblies will not be repeated herein.

Optionally, and with reference to FIG. 21A, a mirror assembly 550includes a reflective element 551 and a mirror housing 552 with amounting portion or ball member 554 formed or positioned thereon. Themirror assembly 550 is mounted at an interior portion of a vehicle, suchas via a mounting or support arm 556 mounted at or attached to amounting portion or base or mirror mount 558 attached to a mountingbutton 560 or the like at an interior surface 562 a of a vehiclewindshield 562. The mirror mount 558 includes a second ball member 564formed thereon and extending at least partially therefrom. The supportarm or element 556 may comprise a split element or tube with a pair ofelements 556 a, 556 b that are positioned apart or separated to allowpositioning of the ball members 554, 564 therein and/or therebetween andthat may be assembled together and clamped or secured or retainedtogether to pivotally receive and retain the ball members 554, 564therein. The elements 556 a, 556 b may each include a partial sphericalpocket or receiving cavity or portion formed on an interior surfacethereof for engaging and receiving the ball member.

The elements 556 a, 556 b may be retained together via any retention orclamping means, without affecting the scope of the present invention.For example, the opposed edges of the elements 556 a, 556 b may bewelded (such as sonic welding or the like) or adhered or bonded or heatstaked together, or the elements 556 a, 556 b may be clamped together orbound together or fastened together (or otherwise mechanically attachedtogether), such as via screws or bands or the like, or the elements 556a, 556 b may snap together or provide other attachment means to readilysecure/retain the elements together when pressed together about the ballmembers. The elements may be formed so that one socket portion is largerthan the other to accommodate different sized ball members within thesupport arm when the support arm is assembled around the ball members.The support element may include external spring elements or the like toenhance the torque at the ball joints. Although shown as pivotallyreceiving a pair of ball members, it is envisioned that the splitsupport arm may attach to a base portion of respective ball portions sothat the ball portions are attached to and extend from opposite ends ofthe split support arm when the split support arm is assembled together.The ball portions may then be pivotally received in respective socketsof the mirror casing and mirror mount.

The split tube support arm 556 may be generally hollow so that wires andthe like may be routed along the tube between the mirror head and themirror mount. Preferably, the ball members 554, 564 may have passagewaysor conduits formed therein and therethrough to allow the wires to passfrom the mirror head (such as from a circuit board within the mirrorhousing) through the ball member 554, through and along the support arm556 and through the ball member 564, where the wire or harness may berouted upward along the windshield to the headliner or roof of thevehicle, such as described above.

Optionally, the mounting arrangements and mirror assemblies of thepresent invention may be utilized with a video slide-out mirror or othervideo displays or screens, such as the types described in PCTApplication No. PCT/US03/40611, filed Dec. 19, 2003, and/or U.S. patentapplication Ser. No. 10/538,724, filed Jun. 13, 2005; and/or Ser. No.10/054,633, filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381, and/orU.S. provisional application Ser. No. 60/630,061, filed Nov. 22, 2004;and Ser. No. 60/667,048, filed Mar. 31, 2005, which are herebyincorporated herein by reference.

As disclosed in Ser. No. 10/054,633, filed Jan. 22, 2002, now U.S. Pat.No. 7,195,381, incorporated above, when a tow hitch initiation event iscontemplated, the driver reverses the vehicle so that a ball member ofthe equipped vehicle is close to a corresponding trailer tongue of atrailer. The field of view of the video imaging sensor (that maycomprise a CMOS or CCD imaging array) is directed to view (or adjustableto view) the approach of the trailer tongue to the ball hitch element.Note that this allows a driver safely hitch a trailer without the needfor a second person to act as a “spotter”, and with the driver beingable to guide successful hitching by viewing the image as presentedwithin the interior cabin while reversing/maneuvering the vehicle. Asalso disclosed in Ser. No. 10/054,633, filed Jan. 22, 2002, now U.S.Pat. No. 7,195,381, incorporated above, and with a TFT LCD video displaydisposed behind the rear substrate of a third-surface transflectiveelectrochromic mirror reflective element in a “display-on-demand”configuration, the presence of (and image displayed by) the videodisplay screen is only principally visible to the driver (who viewsthrough the transflective mirror reflective element) when the videodisplay element is powered so as to project light from the rear of themirror reflective element). Preferably, a single high-intensity powerLED such as a white light emitting LED comprising a Luxeon™ Star PowerLXHL-MW1A white light emitting LED having (at a 25 degree Celsiusjunction temperature) a minimum forward voltage of 2.55 volts, a typicalforward voltage of 3.42 volts, a maximum forward voltage of 3.99 volts,a dynamic resistance of 1 ohm and a forward current of 350 milliamps,and available from Lumileds Lighting LLC of San Jose, Calif. is used asa backlight for the TFT LCD video screen. Alternately, a plurality ofsuch single high-intensity power LEDs (such as an array of two or offour such power LEDs) is placed behind the TFT LCD video screen so thatthe intense white light projected from the individual singlehigh-intensity power LEDs passes through the TFT LCD element and throughthe transflective electrochromic element, preferably producing a displayintensity as viewed by the driver of at least about 200 candelas/sq.meter; more preferably at least about 300 candelas/sq. meter; and mostpreferably at least about 400 candelas/sq. meter. Alternately, coldcathode vacuum fluorescent sources/tubes can be used for backlightingand optionally can be used in conjunction with LED backlighting.

Further, when such a vehicle equipped with such a video mirror is alsoequipped with a side viewing or front viewing or rear viewing sensorvision system (such as by utilizing a radar sensor or an ultrasonicsensor or a camera sensor to monitor an area at or near or adjacent tothe vehicle, such as described in U.S. provisional application Ser. No.60/628,709, filed Nov. 17, 2004; Ser. No. 60/614,644, filed Sep. 30,2004; Ser. No. 60/618,686, filed Oct. 14, 2004; and/or Ser. No.60/638,687, filed Dec. 23, 2004, which are hereby incorporated herein byreference), the video screen may automatically extend when such a sensorsystem detects the presence of an obstacle and/or a human adjacent tothe vehicle. Also, the video display screen may extend in conjunctionwith a trailer-hitch monitoring system (such as the types described inU.S. patent application Ser. No. 10/418,486, filed Apr. 18, 2003, nowU.S. Pat. No. 7,005,974, which is hereby incorporated herein byreference) and icons and/or indicia and/or instructions may be createdon the video image displayed on the extended video screen of the videomirror to assist or guide the driver to hitch a trailer to the trailerhitch of the vehicle.

As disclosed in U.S. patent application Ser. No. 10/418,486, filed Apr.18, 2003, now U.S. Pat. No. 7,005,974, incorporated above, a vehicleimaging system includes an imaging sensor, an image processing system orimage processor and a display. The image processor may receive a signalor image from the imaging sensor and may process the signal to detect atleast one relevant object, such as the vehicle bumper and/or any objector objects near or approaching the vehicle or the vehicle bumper. Theimage processor may provide for edge detection of an object or objectsvia an edge detection algorithm or the like.

The vehicle imaging system comprises an imaging sensor having a field ofview, an image processor and a display. The imaging sensor is operableto generate a signal indicative of an image representative of a sceneoccurring within the field of view. The image processor processes thesignal to detect at least one relevant object within the image. Theimage processor generates an output signal representative of the atleast one detected relevant object.

The display may comprise a dot matrix display.

In applications where a video display screen is extendable/retractable(such as a video slide out device or the like) and/or where a videodisplay screen is activatable/deactivatable (such as a display at orbehind the reflective element or toward the side, such as the passengerside, of the vehicle from the reflective element) in response toengagement of a reverse gear of the vehicle to assist the driver of thevehicle in maneuvering the vehicle in the rearward direction, thedisplay screen may extend (and/or the display may be activated) when thevehicle is shifted into reverse and then may retract (and/or deactivate)when the vehicle is shifted into park or drive or other forward gear. Ina trailer hitching situation, or in other reversing situations, where avehicle is backed up toward a trailer tongue for connecting the trailerto the vehicle (or otherwise backed up toward other objects), thevehicle may be driven backward and forward multiple times to align thevehicle hitch with the trailer tongue (or to align or avoid otherobjects rearward of the vehicle). Such repeated shifting of the vehiclebetween reverse and drive may result in the display beingextended/retracted multiple times and/or activated/deactivated multipletimes, which may also result in the driver losing his or her frame ofreference in the image displayed as he or she repeatedly engages anddisengages the reverse gear of the vehicle. Thus, the circuitry or logicor control of the display of the present invention may extend and/oractivate the display when the reverse gear of the vehicle is engaged,and may maintain the display in the extended/activated state, even ifthe vehicle is shifted into the “drive” gear or any forward gear, untila threshold criteria is met, such as when the forward speed of thevehicle exceeds a threshold speed, such as about 3 miles per hour (mph)or about 5 mph or about 7 mph or about 10 mph (or any desired thresholdvehicle forward speed), or when the vehicle travels in the forwarddirection a threshold distance (such as about 10 feet or about 20 feetor about 30 feet or thereabouts), or when a time period has elapsed fromthe time of disengaging the reverse gear or engaging the forward gear(such as about 5 seconds or about 10 seconds or any other threshold timeperiod after disengaging the reverse gear). The display thus staysextended/activated during short term forward movements, such as maytypically occur during a hitching or other backup or reverse maneuveringevent, in order to provide a continuous display to the driver of thevehicle during the entire hitching or reverse maneuvering operation. Thecamera or imaging device and system may also remain activated so thatthe rearward image is displayed and viewable at the display during thereverse maneuverings and short term forward movements.

For example, and with reference to FIG. 32, a display control system 580includes a control or microprocessor 582 that is operable to control adisplay 584, and that may activate/deactivate the display and/or mayextend/retract the display in response to an activating event ortrigger. In the illustrated embodiment, control 582 extends and retractsdisplay 584 in response to a signal indicative of the transmission gearof the vehicle that is engaged (such as a signal from a shifter or PRNDL586 of the vehicle or the like). The control thus may extend the displayscreen when the reverse gear is engaged, and may retract the displayscreen in response to one or more deactivating or retractingevents/signals. For example, control 582 may retract display 584 whenthe control receives a signal that is indicative of a speed sensor 588(such as a wheel speed sensor or encoder or other speed sensing means)detecting or sensing that the vehicle is traveling forward at or greaterthan a threshold speed, or may retract the display when control 582receives a signal that is indicative of a distance sensor 590 detectingor sensing that the vehicle has traveled forward a threshold distanceafter the reverse gear was disengaged, or may retract the display whencontrol 582 receives a signal that is indicative of a timing device 592signaling that a threshold amount of time has elapsed since the reversegear was disengaged. Other inputs or signals or deactivating events ortriggers that are indicative of the vehicle no longer being in ahitching or other reverse maneuvering situation may be utilized so thatthe control will retract the display after the reverse maneuveringsituation is completed and not during the reverse maneuvering situation.The control thus will not immediately retract the display when theforward gear is engaged but will leave the display extended/activatedduring short term forward movements of the vehicle.

Optionally, and with reference to FIG. 33, a sun visor 594 of a vehicle,such as a driver side sun visor of the vehicle or a passenger side sunvisor of the vehicle, may include a video display screen 596 on itsinward side (the side that faces the headliner 597 when the visor is notflipped down). The video display screen 596 is associated with arearward vision system or back up aid (such as described above) and thesun visor 594 includes a motor or drive mechanism 594 a that is operableto automatically and electrically or electro-mechanically pivot the sunvisor 594 to the lowered position (as shown in FIG. 33) in response tothe reverse gear of the vehicle being engaged, so that the video displayscreen 596 is automatically positioned at a viewable location to displayimages of the scene rearward of the vehicle to the driver of the vehiclewhen the vehicle is shifted into reverse. The motor or drive mechanismmay be operable to raise the sun visor after the reversing maneuver iscompleted. As shown in FIG. 33, sun visor 594 may also include userinputs or buttons 596 a for controlling aspects of the video displayscreen and/or the imaging system and/or other aspects or accessories,such as the volume of associated speakers 598 or the like, which may bepositioned at the sun visor or elsewhere in the vehicle.

In the illustrated embodiment, the motorized/automated sun visor 594with video screen 596 is located at the passenger side of the vehicle.However, a motorized/automated sun visor with video screen may belocated on the driver side of the vehicle, without affecting the scopeof the present invention. It is preferred that the motorized sun visorwith video display screen be positioned at the passenger side of thevehicle to ease viewing of the screen by the driver of the vehicle whenmaneuvering the vehicle in reverse. The sun visor may be pivotable abouta generally vertical pivot axis, and preferably about a generallyvertical pivot axis 594 b that is located at the inward end of the sunvisor (the end of the sun visor that is toward the center of thevehicle), so that the sun visor and video screen may be angled or cantedtoward the driver of the vehicle for enhanced viewing. It is desirableto have the pivot axis of the sun visor at the inward end of the sunvisor so that pivotal movement or canting of the sun visor toward thedriver does not move the sun visor into contact with the windshield ofthe vehicle so that the windshield may not limit or interfere with suchpivoting. The motor or drive mechanism thus may be operable to lower ordescend the sun visor, such as via pivoting the sun visor about agenerally horizontal pivot axis 594 c, to lower or descend the sun visorso that the video screen is viewable by the driver of the vehicle, andthe motor or drive mechanism (or a second motor or drive mechanism) maybe operable to pivot the sun visor about a generally vertical axis 594 bto angle or cant the sun visor and display screen at least partiallytoward the driver of the vehicle. If the display screen is located atthe passenger side sun visor, the screen may be a larger size (than ifit were located at the driver side sun visor) because it is further fromthe eyes of the driver of the vehicle. The sun visor and motor or drivemechanism may have a manual override feature that allows forsubstantially unrestricted manual pivoting or moving of the sun visor sothat the sun visor may be readily pivoted and used by the driver orpassenger of the vehicle during forward driving operations as well.

The motorized flip-down or descending of the sun visor and video screenmay be accomplished via a rotary motor or otheractuating/pivoting/moving device or motor. Such a rotary motor may haverelatively few moving parts and thus may be readily and reliablyimplementable at the sun visor. When the reverse gear is engaged, thevisor thus may automatically flip or descend or lower or pivot downward(and may also pivot toward the driver of the vehicle as discussed above)so that the driver may view in the flipped-down/descended video screenthe reversing image fed from a rear-mounted reversing or trailer-hitchcamera or other rear vision system or back up aid or the like. The sunvisor preferably remains flipped-down/descended until the likes of atime has elapsed (such as about 5 seconds or about 10 seconds orthereabouts) since the reverse gear was first engaged and/or until thevehicle has driven forward a certain distance (such as about 10 feet orabout 20 feet or about 30 feet or thereabouts) and/or until thevehicle's forward speed exceeds a threshold forward speed (such as about3 miles per hour (mph) or about 5 mph or about 7 mph or about 10 mph orthereabouts), in order to limit or reduce or avoid nuisance flipping ordescending of the powered sun visor.

Optionally, and with reference to FIG. 41, a video display screen 686may be extendable or descendible from a screen module or device orassembly or housing or unit 688 via an extendable/retractable device orelement 690. The module 688 may be mountable to a mirror mounting button692 at the windshield of the vehicle and may include a second mountingbutton 693 for mounting a mounting portion 694 of an interior rearviewmirror assembly 696 thereto (such as by utilizing aspects of the modulesdescribed in U.S. Pat. Nos. 6,690,268; 6,824,281 and 5,708,410, whichare hereby incorporated herein by reference). The display screen 686 maybe raisably retractable so as to be in a raised location when not in use(where the screen may be received partially within the module or housingor where the screen may be located at a location where it is not readilyviewable by the driver of the vehicle because it is located generallybehind the mirror assembly 696), and may be lowered or descended to alowered or in use location (as shown in phantom in FIG. 41) where thescreen is readily viewable by a driver of the vehicle. When so lowered,the video screen need not extend entirely below or need not clear thelower portion of the mirror assembly to be readily substantiallyviewable by the driver of the vehicle. The screen may also be pivoted(such as about a generally vertical pivot axis) so as to be angled orcanted toward the driver of the vehicle to enhance viewing of the videoscreen by the driver of the vehicle. Preferably, the video screen isautomatically descendible in response to the vehicle being shifted intoreverse and may remain descended until a threshold forward speed orforward traveled distance is reached by the vehicle or a threshold timehas elapsed after shifting the vehicle out of reverse, such as describedabove.

The display module 688 and video display screen 686 thus may be mountedat an interior portion of the vehicle, such as at an interior surface ofthe windshield of the vehicle, and may provide a button-on-buttonmounting arrangement for the interior rearview mirror assembly 696.Because a mirror mounting button is typically located at the windshieldat a location that is generally above or at least partially elevated ascompared to the height or location of the mirror casing and mirrorreflective element when the mirror reflective element is positioned toprovide a desired rearward field of view to the driver of the vehicle,the location at the windshield generally at or below the mounting buttonis not typically readily viewable by the driver of the vehicle. Thus,the module may be positioned at the mounting button and the videodisplay screen may not be readily viewable until it is lowered ordescended, such as in response to the reverse gear of the vehicle beingengaged.

Although shown and described as extending/descending from a module orhousing or unit, the extending device of the video display screen of thepresent invention may mount to the mounting device and the video displayscreen (such as a screen and frame or casing) may be raised and loweredvia the extending device so as to be moved between the raised andlowered positions, without affecting the scope of the present invention.Also, although shown and described as mounting to the mounting button atthe windshield and providing a second mounting button for the mirrorassembly, the video display screen of the present invention may beattached to or mounted to the mirror mounting portion (such as mountingportion 694 in FIG. 41, and such as by utilizing aspects of the mirrorassemblies described in U.S. Pat. No. 5,708,410, which is herebyincorporated herein by reference), and may extend/descend from themounting portion, which may attach to the mounting button at thewindshield, without affecting the scope of the present invention.

The video display screen thus may be readily lowered to a viewablelocation via extending/retracting device or element 690.Extending/retracting element 690 may comprise any suitable mechanical orelectrical or electro-mechanical means. For example, theextending/retracting element may comprise a telescoping mechanism thattelescopes or elongates to lower the display screen for viewing and thatretracts to raise the display screen to its storage or non-use position,or the extending/retracting element may comprise an accordion-typemechanism or scissor linkage type mechanism or jack type mechanism orslide mechanism or pivot mechanism (that may pivot the screen about agenerally horizontal pivot axis to lower the screen to the viewablelocation) or rack and pinion mechanism or a cylinder or track slidemechanism or any other suitable moving/adjusting mechanism. Theextending/retracting element or device thus may be a relatively simpledevice that moves the screen between the storage or non-use position andthe descended or viewable or in-use position (and may pivot or angle orcant the video display screen toward the driver of the vehicle).Optionally, the video display screen may be fixedly attached to themodule or to the mounting portion of the mirror assembly so as to bereadily viewable by the driver of the vehicle, and may be utilized forvarious applications, such as a backup aid (whereby the video screen maybe automatically activated when the vehicle is shifted into reverse) ora navigation screen or cabin monitor or the like.

The video display screen may be readily attached to the windshieldmounting button and may be provided as an aftermarket device (where themirror assembly may be removed from the windshield mounting button, thevideo screen/module may be attached to the windshield mounting button,and the mirror assembly may be mounted to or attached to the button onthe module). The video display screen may comprise any suitable displayscreen, such as an LCD screen or the like, such as a screen having awidth or diagonal dimension of approximately 2.5 inches to about 3.5inches or thereabouts. Although shown as a downwardly movable displayscreen, the video display screen may be movably adjusted orextended/retracted in a sideward direction, so as to extend toward oneside or the other for viewing by the driver of the vehicle. Inapplications where the display screen is extended toward the passengerside (and thus away from the driver of the vehicle), the display screenmay be selected to be a larger size as compared to applications wherethe display screen is extended toward the driver side of the vehicle.Also, it may be desirable to angle or cant the display toward the driverof the vehicle for enhanced viewing of the display screen, particularlyfor applications where the display screen is extended away from thedriver of the vehicle.

The display screen may be purchased as a relative small, self-containedbox or module that includes the display screen, frame or housing andelectronic circuitry for the display screen. The display screen framemay then be attached to a suitable extending/retracting device orelement that functions to selectively lower and/or pivot the displayscreen for viewing by the driver of the vehicle. Theextending/retracting device may be mounted or attached to the mirrormount or to a module or base of the display screen so as to move thevideo display screen relative to the mirror mounting button area at thewindshield. The video display screen of the present invention thus mayutilize the area along the windshield generally below the mirror mountor mounting button that is not readily viewable by the driver of thevehicle because that area is generally or partially blocked from thedriver's forward field of view by the mirror assembly and reflectiveelement and casing of the mirror assembly.

Optionally, and with reference to FIGS. 22-24, a mirror assembly 610 mayinclude a support assembly 612 that supports or mounts a mirror housing618 and reflective element assembly 614 at an interior portion of avehicle, such as at a mounting button at a windshield of a vehicle. Thesupport assembly may include a mounting or support arm 622 and mirrormount or base portion 624, such as described above. The reflectiveelement may comprise an electro-optic reflective element assembly, suchas an electrochromic reflective element assembly, or a prismaticreflective element. In the illustrated embodiment, the reflectiveelement comprises an electro-optic reflective element assembly, such asan electrochromic reflective element assembly utilizing principlesdescribed in U.S. provisional application Ser. No. 60/553,842, filedMar. 17, 2004; Ser. No. 60/563,342, filed Apr. 19, 2004; and Ser. No.60/629,926, filed Nov. 22, 2004, and/or PCT Application No.PCT/US03/29776, filed Sep. 19, 2003; and/or PCT Application No.PCT/US03/35381, filed Nov. 5, 2003; and/or PCT Application No.PCT/US2004/015424, filed May 18, 2004, and/or U.S. patent applicationSer. No. 10/528,269, filed Mar. 17, 2005, now U.S. Pat. No. 7,274,501;Ser. No. 10/533,762, filed May 4, 2005, now U.S. Pat. No. 7,184,190;Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451,which are all hereby incorporated herein by reference. The reflectiveelement assembly 614 includes a front substrate 670, a rear substrate671, and an electrochromic medium 672 disposed between the substratesand substantially contained by a seal 674. The reflective elementassembly may include a perimeter band or coating and/or other indicia ormarkings, such as by utilizing aspects described in U.S. patentapplication Ser. No. 10/533,762, filed May 4, 2005, now U.S. Pat. No.7,184,190; and/or Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S.Pat. No. 7,255,451, and/or U.S. provisional application Ser. No.60/681,250, filed May 16, 2005; Ser. No. 60/690,400, filed Jun. 14,2005; Ser. No. 60/695,149, filed Jun. 29, 2005, which are herebyincorporated herein by reference.

As shown in FIGS. 23 and 24, the front substrate 670 includes aperimeter or perimetal border coating 676 (not shown in FIG. 22) on itssecond surface 670 b (opposite to the first surface 670 a that faces thedriver of the vehicle when the mirror assembly is installed in thevehicle). The perimetal coating 672 includes an enlarged area or region674, such as along a lower region of the reflective element. The seal674 (which seals the electrochromic medium 672 between the frontsubstrate 670 and rear substrate 671) is disposed between the perimeterregions of the substrates and generally along the perimetal coating 676,and is generally concealed or hidden by the coating 676 so that the sealis not readily viewable through the front substrate by an occupant ofthe vehicle. The seal 674 thus may follow the shape of the coating, andmay follow or be disposed along the bump or enlarged area or region 678,such that the seal and reflective element may define or provide a regionoutside of the seal but within the perimeter of the front substrate forpositioning one or more accessories or the like. The accessories, suchas sensors 680 a, 680 b, may be disposed or positioned at the coating676 and outside of the seal 674, such that the reflective elementassembly may include such accessories or sensors or inputs within theperimeter regions of the front substrate, thereby providing a generallyflush or frameless reflective element and mirror assembly.

The perimetal coating 676 provides an outer area or region at the backsurface of the front substrate and includes the bump or enlarged area orregion 678 outward from the seal (and thus not behind anelectro-optically dimmable portion of the mirror reflector) forpositioning sensors, such as glare sensors, photo sensors, touch sensorsor proximity sensors or the like. The perimetal or border coating orlayer may comprise a reflective coating (such as a metallic thin filmcoating) or a non-reflective coating (such as a dark paint or ink orfrit or a non-reflecting or poorly reflecting film), and may besubstantially opaque or may be at least partially light transmitting (orthere may be a local region within the bump or enlarged area or region678 that is at least partially light transmitting so that a photo sensorcan be disposed at this local light transmitting region and have a fieldof view through the perimetal or border coating and so detect, forexample, glaring headlights from a rear approaching vehicle when theessentially frameless interior rearview mirror assembly is mounted inthe interior cabin of the host vehicle), without affecting the scope ofthe present invention.

The border or perimetal coating 676, including its portion forming bumpor enlarged area or region 678, is preferably selected so as to at leastpartially (and more preferably substantially, and most preferablycompletely) conceal or hide the seal that is disposed around theelectrochromic medium and between the substrates. For applications witha glare sensor (where the sensor senses light from the rear of thevehicle and thus receives light through the front substrate), thecoating is at least partially light transmitting at least in the regionwhere the glare sensor is positioned. The sensors may be arranged on theenlarged region above and below one another (as shown in FIG. 24), ormay be arranged side by side one another or in any other desired orappropriate pattern or arrangement, without affecting the scope of thepresent invention. The sensors may comprise glare sensors or photosensors (such as sensors of the types described in U.S. Pat. Nos.4,793,690 and 5,193,029, and U.S. patent application Ser. No.10/512,206, filed Oct. 22, 2004, now U.S. Pat. No. 7,110,156; Ser. No.10/514,709, filed Nov. 17, 2004, now U.S. Pat. No. 7,242,320; and/orSer. No. 10/456,599, filed Jun. 6, 2003, now U.S. Pat. No. 7,004,593,which are all hereby incorporated herein by reference), or touch orproximity sensors (such as the sensors of the types described in PCTApplication No. PCT/US03/40611, filed Dec. 19, 2003; and/or U.S. patentapplication Ser. No. 10/956,749, filed Oct. 1, 2004, now U.S. Pat. No.7,446,924; and/or Ser. No. 10/933,842, filed Sep. 3, 2004, now U.S. Pat.No. 7,249,860, which are all hereby incorporated herein by reference).

The perimeter coating thus provides a coating or portion for the seal tobe disposed along, in order to shape the seal so that a region is formedoutside of the seal but within the perimeter of the front substrate. Thecoating may thus provide an outer area for a function, such as touchsensing, proximity sensing, light sensing and/or glare sensing viasensors positioned at the outer area. The coating and substrate of thepresent invention thus are suitable for use in a frameless mirrorassembly, while providing functionality at the reflective element. Asshown in FIG. 22, the front substrate may be offset or larger than therear substrate so as to provide an overhang region 682 a, 682 b alongthe upper and/or lower perimeter regions. The accessory or sensor orsensors may be positioned along the overhang region, such as along thelower overhang region 682 b.

In accordance with this aspect of the present invention, an essentiallyframeless interior mirror assembly (whether an electrochromic mirrorassembly or a prismatic mirror assembly) can be formed where a useractuation interface is provided as a human machine interface, withouthaving to create a gondola protrusion or bulge below the overall stylingline defined by the interior mirror shape itself (and thus avoids anyinterference with a driver's forward field of view through thewindshield of the vehicle), or without having to create an eyebrowprotrusion or bulge above the overall styling line defined by theinterior mirror shape itself (and thus avoids any interference with adriver's forward field of view through the windshield of the vehicle).However, should such protrusions or bulges be small/compact (less thanabout 1.5 cm protrusion from the line of the mirror shape preferred;less than about 1 cm more preferred; and less than about 0.75 cm mostpreferred), they can optionally be used alone or in combination with theperimetal/border coating 676 (including its portion forming bump orenlarged area or region 678) of the present invention.

Although shown and described as being a coating around the perimeter ofan electrochromic reflective element assembly, the perimetal coating(for example, a layer of chromium or of rhodium or of rhodium/chromium)may be disposed around the perimeter edge or region of other reflectiveelements, such as prismatic reflective elements or the like. Whendisposed on prismatic reflective elements, the coating may only bedisposed at the region at which the sensors are positioned, since thecoating around the other portions or regions is not necessary, sincethere is no seal to hide or conceal on a prismatic reflective elementassembly. Optionally, when one exterior side rearview mirror has anelectro-optic reflective element (as is typically located at the driverside of the vehicle) and the other exterior side rearview mirror has acurved reflective element or non-electro-optic reflective element (asmay be provided at the passenger side of the vehicle), a matchingperimeter band may be disposed around the non-electro-optic reflectiveelement so that the perimeter band of the passenger side mirror matchesthe perimeter band of the driver side mirror, such as by utilizingaspects described in U.S. provisional application Ser. No. 60/681,250,filed May 16, 2005; Ser. No. 60/690,400, filed Jun. 14, 2005; Ser. No.60/695,149, filed Jun. 29, 2005, which are hereby incorporated herein byreference. Optionally, for applications where the perimeter bandmaterial of the electrochromic or driver side mirror is selected to bethe same as or substantially the same as the third surface reflectormaterial, the optical match (as viewed by a person viewing thereflective element) between the perimeter band and the third surfacereflector may be sufficient so that the perimeter band is not readilydiscernible at the mirror reflector. Thus, in such applications, it maynot be necessary to provide a perimeter band on the correspondingconventional (such as chrome or titanium or “Blue” coated), non-ECpassenger side exterior mirror reflective element.

Also, when a perimetal coating 676 (including its portion forming bumpor enlarged area or region 678) is used with an electro-optic mirrorcell (such as an electrochromic mirror cell) that comprises a frontsubstrate and a rear substrate sandwiching an electro-optic medium andspaced apart by a perimetal seal, the sensors, such as a photosensor andone or more proximity sensors, can be disposed behind the rear substrate(i.e. behind the fourth surface of the twin-substrate laminate) or therear substrate can be notched at a portion that corresponds with andjuxtapositions with the bump or enlarged area or region 678 of thecoating 676, so that the sensors can be disposed directly behind thefront substrate (the second surface of the twin-substrate laminate).

Optionally, the mirror assembly may include one or more photo sensors,such as for sensing ambient light and glare at the mirror assembly. Thesensors may be attached to a printed circuit board, such as by utilizingaspects described in U.S. patent application Ser. No. 10/512,206, filedOct. 22, 2004, now U.S. Pat. No. 7,110,156, which is hereby incorporatedherein by reference. The photo sensor may be generally flat, rectangularsensor on an arm with a plurality of pins or contacts or terminals (suchas, for example, three or five pins) extending therefrom for electricalconnection to the circuit board. The sensor or sensors may comprise dualin-line photodiodes or phototransistors established on a commonsemi-conductor substrate (such as a silicon substrate). An infrared (IR)filter and light transmitting lens may be disposed at the sensors.Optionally, the sensors and associated circuitry may be established on asubstrate or chip, such as by utilizing aspects of the ECdriver-on-a-chip described in U.S. patent application Ser. No.11/201,661, filed Aug. 11, 2005, now U.S. Pat. No. 7,480,149, which ishereby incorporated herein by reference. The sensor or sensors may beattached to the circuit board and positioned to align the sensing faceof each sensor with an aperture or port of the mirror forreceiving/sensing light at the photo sensor. Optionally, the sensors mayattached to and positioned at the rear surface of the circuit board (thesurface that faces away from the rear surface of the reflective element)and one photodiode may be aligned with an aperture or port formedthrough the circuit board, such that the sensing face of the photodiodesenses light that is received through the reflective element and throughthe aperture or port in the circuit board, while the other photodiode isaligned with an aperture in the casing (such as an aperture at a lowerportion of the casing or elsewhere at the casing) to receive ambientlight from a lower region of the mirror assembly or the like.Optionally, one or both of the sensors or photodiodes may be positionedor oriented so as to generally align with a light pipe or the like fordirecting ambient or glare light along the light pipe to the sensor orsensors. For example, the light pipe or pipes may utilize aspects of thelight-piping described in U.S. patent application Ser. No. 10/229,573,filed Aug. 28, 2002, now U.S. Pat. No. 7,008,090, which is herebyincorporated herein by reference.

For the third surface metallic reflectors, second surface metallicreflective bands and/or fourth surface wrap-around metallic conductorlayers (such as are disclosed in U.S. patent application Ser. No.11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451; and/orU.S. provisional application Ser. No. 60/644,903, filed Jan. 19, 2005;and Ser. No. 60/667,049, filed Mar. 31, 2005, which are herebyincorporated herein by reference), thin film coatings formed preferablyby sputtering of nickel-alloys or iron-alloys can be used.

For example, Inconel (a nickel-based superalloy such as Inconel alloy600 which is 72 percent nickel, 16 percent chromium, and 8 percent iron)can be used. Other forms of Inconel can be used, depending on theproperty required for a particular mirror construction/coating. Forexample, Inconel alloy 750, which has a small percentage of titanium andaluminum added for hardenability, can be used. Another example of asuitable material is Inconel 625, which contains molybdenum andcolumbium.

Another suitable nickel-alloy choice is HASTELLOY, which is a registeredtrademark name of Haynes International, Inc. The predominant alloyingingredient is typically nickel. Other alloying metals may be added tothe nickel, including varying percentages of the elements molybdenum,chromium, cobalt, iron, copper, manganese, titanium, zirconium,aluminum, carbon, and tungsten. For example, for the third surfacemetallic reflectors, second surface metallic reflective bands and/orfourth surface wrap-around metallic conductor layers of theelectrochromic mirrors described herein, thin film coatings may bedeposited on the substrates involved by sputtering in a vacuum chamberfrom a Hastelloy C 276 or a Hastelloy X alloy planar magnetron or rotarymagnetron sputtering target.

Another suitable choice is Nichrome, which is an alloy of nickel andchromium. Typically, the alloy is 80 percent nickel and 20 percentchromium. Nichrome, when sputter deposited as a conductive, metallic,reflective thin film of at least about 300 angstroms thickness has aspecular reflectivity greater than about 60 percent reflectivity; anddepending on the vacuum deposition conditions greater than about 65percent reflectivity (as measured using SAE J964a). For example, goodresults can be achieved using a thin film of Nichrome [typically about400-600 angstroms thick sputter-deposited onto the inward-facing surface(third surface) of the rear substrate in a laminate-type electrochromicmirror cell construction], and then overcoating this thin layer ofNichrome with a thinner layer (typically about 100-200 angstroms thickor thereabouts) of Rhodium to form a Nichrome/Rhodium third surfacereflector. If Nichrome is also used as a wrap-around fourth surfaceconductor [or for the perimetal reflector band around the edge perimeterof the inward-facing surface (second surface) of the front substrate ofthe EC cell construction], contact resistance challenges sometimesexperienced when a chromium thin film conductor layer is contacted to bysome silver-loaded conductive epoxies are reduced/mitigated.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayers is a coating of Nickel Silver, which is an alloy of copper withnickel and often, but not always, zinc. Nickel-silver alloys arecommonly named by listing their percentages of copper and nickel, thus“Nickel Silver 55-18” would contain 55 percent copper, 18 percentnickel, and 27 percent other elements, most probably entirely zinc. Forexample, a NS-12 Nickel-silver alloy, which is 88 percent copper and 12percent nickel, may be used.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayers is a coating of Cupronickel which is an alloy of copper, nickeland strengthening impurities. A typical mix is 75 percent copper, 25percent nickel, and a trace amount of manganese. A 55 percent copper/45percent nickel alloy may also be used.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayers is a coating of Monel metal, which is a copper-nickel alloy.Monel is a metal alloy, primarily composed of nickel and copper, withsome iron and other trace elements. Also, bronze (copper alloyed withtin), brass (copper alloyed with zinc), and nickel silver (another groupof copper-nickel alloys) may be used.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayers is a coating of stainless steel which is a ferrous alloy with aminimum of 10.5 percent chromium, preferably with additions of more than12 percent (by weight) chromium. For example, a thin film coatingsputtered off an AL-6XN alloy target, which is a superausteniticstainless steel which was developed by Allegheny Ludlum Corporation(www.alleghenyludlum.com), can be used. It exhibits far greaterresistance to chloride pitting, crevice corrosion and stress-corrosioncracking than exhibited by the standard 300 series stainless steels, andis less costly than traditional nickel-base corrosion resistant alloys.The UNS Designation of the AL-6XN® alloy is N08367.

The high nickel (24 percent) and molybdenum (6.3 percent) contents ofthe AL-6XN® alloy give it good resistance to chloride stress-corrosioncracking. The molybdenum confers resistance to chloride pitting. Thenitrogen content of AL-6XN® alloy serves to further increase pittingresistance and also gives it higher strength than typical 300 seriesaustenitic stainless steels, and thereby often allows it to be used inthinner sections. The high levels of chromium, molybdenum and nitrogenin AL-6XN® alloy all serve to produce exceptional corrosion resistancefor this formable and weldable stainless steel.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayers is a coating of Chinese silver, which is an alloy made of silver,nickel and bronze, such as used for jewelry or a coating of a Ferroalloythat constitutes various alloys of less than 50 percent iron and one ormore other element, manganese or silicon for example. The mainFerroalloys are: ferromanganese, ferrochromium, ferromolybdenum,ferrotitanium, ferrovanadium, ferrosilicon, ferroboron, andferrophosphorus.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a coating of German silver that is an alloy of 45-70 percentcopper, 5-30 percent nickel, and 8-45 percent zinc-sometimes smallamounts of tin or lead are added. It has a color resembling silver.Other names are Nickel silver, Pakfong (also Paktong) and Alpacca(originally a trademark of Berndorf AG).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a coating of a titanium alloy such as a Grade F-5 titaniumalloy (6 percent aluminum, 4 percent vanadium); Grade F-6 titanium alloy(5 percent aluminum, 2.5 percent tin); a titanium/palladium alloy; GradeF-12 titanium alloy (0.3 percent molybdenum, 0.8 percent nickel).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a coating of a manganese alloy, such as a manganese-copper or amanganese-iron or a manganese-gold alloy. Another alloy choice for thesemetal reflector and/or conductor layers is a coating of a molybdenumalloy, such as a 52 percent molybdenum/48 percent rhenium alloy or a 99percent Mo, 0.5 percent Ti and 0.08 percent Zr alloy (commonly known asa TZM alloy).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is Sterling silver, which is an alloy of silver containing least92.5 percent pure silver and 7.5 percent other metals, usually copper.In Sterling silver, the silver is usually alloyed with copper to givestrength. Other metals can replace the copper. For example, a thin filmcoating formed by sputter deposition from a Silver/Germanium alloytarget can be used.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is an aluminum alloy, such as Duralumin which is an alloy ofaluminum (about 95 percent), copper (about 4 percent), and small amountsof magnesium (0.5 percent to 1 percent) and manganese (less than 1percent). When sputter deposited to form a thin film metallic conductorreflector/electrode layer, such aluminum alloy thin films may optionallybe overcoated with a thin film of a transparent conductor (such as ofindium tin oxide) that is thus disposed between the aluminum-basedreflector layer and the electrochromic medium in the electrochromic cellconstruction (and thus protecting the aluminum-based reflector layerfrom direct contact with the electrochromic medium).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is Stellite, which is a range of cobalt-chromium alloys designedfor wear resistance. It may also contain tungsten and a small butimportant amount of carbon.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is Billon, which is an alloy of silver (sometimes gold) with ahigh base metal content (such as copper) or a silver alloy such as asilver-palladium alloy.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are copper-zinc-aluminum alloys or nickel-titanium (NiTi) alloys,such as the nickel-titanium alloy available under the trade name Nitinol(an acronym for Nickel Titanium Naval Ordnance Laboratories).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are tungsten alloys with tungsten content ranging from 40 to 97percent featuring varying degrees of physical and mechanical properties;examples include W—Fe, W—Cu and W—Co alloys.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are palladium alloys, such as palladium-rhodium alloys.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are indium alloys, such as indium-bismuth-tin alloys orlead-indium alloys or tin-indium alloys.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are zinc alloys, such as with copper or magnesium or nickel.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is Brass, which is an alloy of copper and zinc. Some types ofbrass are called bronzes, despite their high zinc content. Alpha brasses(with less than 40 percent zinc) or Beta brasses, with a higher zinccontent, can be used, depending on the circumstance involved. Whitebrass, with more than 45 percent zinc, can also be used when it deliversthe desired property.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a rhenium alloy, such as a molybdenum-rhenium or atungsten-rhenium alloy.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a gold alloy such as an ELKONIUM® 76 gold-copper alloy or anELKONIUM® 70 gold-silver-nickel alloy or a gold-palladium-nickel alloyor a gold-copper alloy or a gold-copper-nickel alloy or a gold-indiumalloy or gold-nickel alloy or a gold-tin alloy.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a platinum alloy, such as with cobalt, or with copper or withiridium (for example, Pt70/Ir30) or with palladium or with rhodium orwith gallium or with ruthenium or with tungsten or with indium.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a rhodium alloy, such as with iron or platinum (for example,Pt90/Rh10 or Pt87/Rh13).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a cobalt alloy, such as with iron or nickel.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a copper alloy, such as with tin or nickel or lead. Examplesinclude Phosphor Bronze, Gun Metal, Tin Bronze, Leaded Bronze and NickelBronze.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are superalloys, such as PM200 available from Plansee AG ofReutte, Austria, and having a composition in weight percentage: 20 Cr,5.5 Al, 0.5 Ti, 0.3 Al, 0.5 Y2O3, remainder Fe. The Plansee PM 2000 is ahighly oxidation resistant and extremely creep resistant ferriticiron-chromium based alloy, due to its high content of aluminum andchromium.

Another alloy choice for these third surface metal reflector layers,second surface indicia reflective bands/indicia layers and/or fourthsurface conductor layers are tantalum alloys, such as tantalum-tungstenalloys and tantalum-niobium alloys. Another alloy choice for these metalreflector and/or conductor layers are niobium alloys or zirconium oriridium alloys or osmium alloys or ruthenium alloys or lead alloys orberyllium alloys or tin alloys.

Alloys formed of tin and lead with other metal elements and non-metalelements (such as phosphorous or silicon or carbon) may be used wherethe coating properties suit the particular electrochromic cellstructure/performance desired.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a magnesium alloy, such as Magnesium-manganese;Magnesium-aluminum-manganese; Magnesium-aluminum-zinc-manganese;Magnesium-zirconium; Magnesium-zinc-zirconium; Magnesium-rare earthmetal-zirconium; Magnesium-silver-rare earth metal-zirconium; and/orMagnesium-yttrium-rare earth metal-zirconium.

Metal reflector layers and/or indicia layers and/or conductor layers mayalso be sputter (or otherwise) deposited from metal targets such as froma chromium metal target, or from a nickel metal target or from atungsten metal target or from a ruthenium metal target or from atitanium metal target or from a molybdenum metal target or from a cobaltmetal target or from a manganese metal target or from a silver metaltarget or from an aluminum metal target or from a platinum metal targetor from a palladium metal target or from a gold metal target or from arhenium metal target or from a rhodium metal target or from a tantalummetal target or from a niobium target or from a zirconium target or froman iridium target or from an osmium target or from a lead target or froma beryllium target or from a zinc target or from a tin target or from anindium target or from a target that is a mixture of one or more of thesemetals (optionally with other metallic and/or non-metallic elementsincluded). In general, improved results in terms of making contactthereto, such as via a conductive epoxy (such as lower, stabler contactresistances), are obtained for metal reflector and/or conductor layersby using metals or alloys that have a low Gibbs Energy of formation ofmetal oxides as the sputter target (or evaporation material) for vacuumdeposition of thin metallic layers. For example, deposited thin films ofpalladium or nickel or tungsten or molybdenum or rhodium have a lowGibbs Energy of formation of metal oxides compared to, for example, thinfilms of aluminum or chromium.

The choice of alloy or metal reflector and/or conductor layer to use isdependent on the reflectivity level and spectral content desired (forexample, whether a silvery reflectivity is desired or whether a morecopper-toned reflectivity is desired) and by the electrical properties(such as specific conductivity of the deposited thin film) and/oroptical properties (such as the optical constants such as refractiveindex and k-value) desired for the deposited thin metallic film and/orby the sputtering rate/evaporation rate desired in the productionprocess and/or by the cost bearable by the construction involved.

Also, when sputtering or otherwise vacuum depositing the metal reflectorand/or conductor layers of the present invention from an alloy ormixed-metal target or source, the elemental composition/structure of thetarget/source is preferably substantially replicated in the depositedmetallic thin film coating or layer but need not be exactly replicated.

Also, and as described previously above and optionally, the thirdsurface metal reflector on the third surface of the rear substrate ofthe cell, the perimeter reflective border band around the edge border ofthe second surface of the front substrate and any indicia on the secondsurface but inward of the border band (if present) may be substantiallythe same material so that all three have substantially the same opticalproperties such as reflectivity level and refractive index/k-value. Byso choosing, the optical contrast between the third surface reflectorcoating and the second surface perimeter border is substantially reducedand essentially eliminated such that the viewer barely sees or noticesthe presence of the second surface border band when the electrochromiccell is not powered (i.e. is undimmed and is in its bleached state). Forexample, the third surface reflector coating and the second surfaceperimetal border reflector band may both comprise chromium thin films orboth may comprise ruthenium thin films or both may comprise rhodium thinfilms or both may comprise Hastelloy C-276 thin films or both maycomprise molybdenum thin films or both may comprise aluminum (oraluminum alloy) thin films or both may comprise aluminum/palladium alloythin films or both may comprise silver (or silver alloy) thin films orboth may comprise an ITO/thick Ag (preferably greater than about 200angstroms physical thickness; more preferably greater than about 250angstroms thickness and most preferably greater than about 300 angstromthickness)/ITO stack or a ZnAlO/thick Al/ZnAlO stack or a ZnAlO/thickAg/ZnAlO stack or an SnO2/Ag/SnO2 stack or the like.

Optionally, and with reference to FIG. 25, a reflective element assembly710 includes a reflective element 714 received within and/or held and/orsupported by a support element 750. The support element 750 includesperimeter walls 752 and a back portion 754, which cooperate to define apocket or cavity in which the reflective element 714 is received. Theperimeter walls 752 include an outer lip portion or shoulder portion756, which extends at least partially or slightly over the perimeterregion of the front surface 720 a of the reflective element 714, inorder to retain the reflective element within the cavity of the supportelement and between the back portion 754 and the lip portion 756.

In the illustrated embodiment, the reflective element 714 comprises anelectro-optic or electrochromic reflective element having a frontsubstrate 720 and a rear substrate 722 and an electro-optic medium 724disposed therebetween and substantially encompassed by a perimeter seal726 around the electro-optic medium and between the substrates 720, 722.The electro-optic reflective element includes a transparent conductivecoating or layer 728 substantially over the rear surface 720 b of frontsubstrate 720 and a metallic reflective conductive coating or layer (orcoatings or layers) 730 substantially over the front surface 722 a ofthe rear substrate 722. The coatings may comprise any suitableconductive and reflective/transparent coatings or layers, such as thetypes described in U.S. Pat. Nos. 6,690,268; 5,668,663 and/or 5,724,187,and/or in U.S. patent application Ser. No. 10/054,633, filed Jan. 22,2002, now U.S. Pat. No. 7,195,381; Ser. No. 10/528,269, filed Mar. 17,2005, now U.S. Pat. No. 7,274,501; Ser. No. 10/533,762, filed May 4,2005, now U.S. Pat. No. 7,184,190; and/or Ser. No. 11/021,065, filedDec. 23, 2004, now U.S. Pat. No. 7,255,451; and/or PCT Application No.PCT/US03/29776, filed Sep. 9, 2003; and/or PCT Application No.PCT/US03/35381, filed Nov. 5, 2003; and/or U.S. provisional applicationSer. No. 60/630,061, filed Nov. 22, 2004; Ser. No. 60/667,048, filedMar. 31, 2005; Ser. No. 60/629,926, filed Nov. 22, 2004; Ser. No.60/531,838, filed Dec. 23, 2003; Ser. No. 60/553,842, filed Mar. 17,2004; Ser. No. 60/563,342, filed Apr. 19, 2004; Ser. No. 60/681,250,filed May 16, 2005; Ser. No. 60/690,400, filed Jun. 14, 2005; and/orSer. No. 60/695,149, filed Jun. 29, 2005, and/or PCT Application No.PCT/US03/40611, filed Dec. 19, 2003, which are all hereby incorporatedherein by reference. As shown in FIG. 25, the rear substrate may have asmaller width or height or length dimension so that the reflectiveelement has overhang regions 715 a, 715 b along respective edge portionsof the reflective element, such as described in U.S. patent applicationSer. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451,which is hereby incorporated herein by reference. Although shown anddescribed as an electro-optic or electrochromic reflective element, thereflective element may comprise any other type of mirror reflectiveelement, such as a prismatic reflective element or the like, withoutaffecting the scope of the present invention.

Support element 750 is preferably molded from a substantially rigidthermoplastic material, such as a polyolefin, such as a polypropylene orthe like, or a substantially rigid thermoset polymeric resin, such as aNylon or a urethane or the like; but a flexible polymeric or elastomericmaterial may also or otherwise be used, such as in applications wherethe structural integrity of the support element is less utilized. Theperimeter wall portion 752 may flex to allow the reflective element tobe inserted through the front of the support element, so that thereflective element 714 (which is oversized relative to the lip portion756 and thus has perimeter dimensions greater than the perimeterdimensions of the perimeter edges 756 a of the lip portion 756) mayinsert through the lip portion 756. When the reflective element isinserted within the cavity defined by the perimeter wall portion andback portion, the perimeter wall portion 752 may flex back toward itsinitial orientation, whereby the lip portion 756 will overlap theperimeter edge regions of the front surface 720 a of the reflectiveelement 714. Preferably, the lip portion 756 will overlap the frontperimeter regions a small amount, such as about 1 mm or thereabouts, soas to provide a small or low profile lip or shoulder and thus asubstantially frameless appearance to the reflective element. As can beseen in FIG. 25, the support element 750 may include a groove or notchportion 758 along and at least partially around the perimeter wallportion 752, and may be near or proximate to the back portion 754, tofacilitate flexing of the perimeter wall portion 752 during insertion ofthe reflective element into the support element. Because the material ofthe support element may comprise a substantially rigid material, thegroove or notch (or any other means for weakening or flexing thesidewalls of the support element, such as a narrowed wall thickness orthe like) facilitates flexing of the sidewalls as the reflective elementis inserted into or press fit the pocket or cavity of the supportelement. The groove or notch or narrowed wall thickness thus allowsflexing outward of the sidewalls and gives a springiness to thesidewalls so that they readily return to or are biased toward theirinitial orientation after the reflective element is inserted past thelip portion of the support element.

As shown in FIG. 25, support element 750 may include one or moreattachment elements or structure 760, such as tabs or the likeprotruding rearward from the rear or back portion 754, for attaching aback plate and/or printed circuit board or the like (not shown in FIG.25) to the reflective element assembly 710. The attachment elements 760may attach or secure or retain the reflective element assembly 710 tothe back plate (such as a back plate and circuit board assembly with theassociated accessories or circuitry or the like, or such as a back plateor mounting plate having the mounting portion (such as a socket forreceiving a ball member of a mounting arm or the like) for adjustablymounting the reflective element assembly to a mounting structure). Thereflective element assembly and mounting plate thus may be readilypositioned in or at or attached to a mirror mounting structure and/ormirror casing.

Optionally, the back portion 754 may include one or more viewingapertures or openings 762 formed therethrough. The viewing apertures 762may be formed to correspond or align with a display element (not shown)of the circuitry or circuit board of the mirror assembly, such thatinformation or icons or indicia or the like emitted or projected or backlit by the display element may be viewable through the reflectiveelement and the viewing aperture so as to be viewable at the reflectiveelement by a driver of the vehicle. The viewing apertures 762 may beopenings through the back portion 754, or may comprise a transparent orsubstantially transparent or translucent element, such as a plastic orclear lens or optic or the like (and may have an icon or symbol orinformation or indicia formed thereon so as to be backlit by the displayelement or illumination source at the rear of the reflective element),in order to provide optical coupling between the display element and therear surface 722 a of the reflective element 714. The display element ordevice may comprise any suitable display element or device orillumination source, such as those described below, without affectingthe scope of the present invention.

In the illustrated embodiment of FIG. 25, reflective element 714comprises an electro-optic or electrochromic reflective element withfourth surface electrically conductive bus-bars or elements 764, 766 atthe rear surface 722 b of rear substrate 722 of reflective element 714.The fourth surface electrically conductive bus-bars 764, 766 may includewrap-around conductive portions 764 a, 766 a to electricallyconductively connect the fourth surface conductive bus-bars 764, 766 tothe third surface conductive coatings or layers 730 or second surfacetransparent conductive coating or layer 728, respectively, such as byutilizing principles described in U.S. patent application Ser. No.11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451; and/orU.S. provisional application Ser. No. 60/644,903, filed Jan. 19, 2005;and Ser. No. 60/667,049, filed Mar. 31, 2005, which are herebyincorporated herein by reference. As shown in FIG. 25, the wrap-aroundportion 766 a may extend along the edge of the rear substrate and alongthe seal to contact the second surface conductive coating 728 and/or theperimetal border coating 776 (and may comprise a conductive epoxy orsolder material or the like disposed at the overhang region 715 a of thereflective element 714). In such applications, the back portion 754 mayinclude electrical connection apertures 768, 770 to allow for electricalcontact or connection between circuitry of the back plate and/or circuitboard or the like and the fourth surface bus-bars 764, 766,respectively. The electrical contacts or connectors of the mirrorcircuitry may insert through the apertures 768, 770 in the back portion754 and into electrically conductive contact with the respective fourthsurface bus-bars 764, 766. Electrical connection between the circuitrycontacts and the fourth surface bus-bars 764, 766 may be established andmaintained via conductive epoxy or solder or the like, or via mechanicalconnection of the circuitry contacts to the bus-bars or biasing of thecircuitry contacts to the bus-bars or the like, without affecting thescope of the present invention. Optionally, the support element mayinclude metallic or conductive posts or columns or connectors molded orformed or positioned through the back portion so that the integralconductive posts may electrically conductively contact/connect to thefourth surface electrical connection sites or regions, such as bus-bars,when the reflective element is inserted or press fit into the supportelement. The conductive posts may protrude rearward from the rearsurface of the back portion (the surface facing away from the rearsurface of the reflective element) or may be otherwise exposed at therear surface of the back portion so as to facilitate electricalconnection when the circuit board is attached to the support elementand/or when the reflective element is installed in the mirror casing.

The spring loaded or biased or urged contacts, besides making electricalcontact, may also provide substantially secure mechanical contact of thecontacts or terminals of the mirror assembly, whereby the contacts orterminals may be soldered or spot welded or adhered to secure thecontacts/terminals together. Because the contacts are mechanically urgedtogether, a local spot weld or solder (such as an automatically appliedsolder joint) or conductive epoxy may be readily applied to the joint toaugment the mechanical connection to ensure that electrical contact issecured. Such a welding or soldering or conductive material adheringstep may be readily accomplished, without having to also hold theconnectors together during the welding/soldering/adhering operation. Thesecuring of the connectors thus may be accomplished in situations whereit is difficult to access or view the connection. For example, inapplications where the components are loaded or assembled along a singlez-axis (such as described in U.S. patent application Ser. No.10/933,842, filed Sep. 3, 2004, now U.S. Pat. No. 7,249,860, which ishereby incorporated herein by reference), one of the components may havea curable conductive epoxy applied thereto, whereby the epoxy willcontact and secure the connections together after the connections areurged together and held together during the assembly process. As theconductive epoxy (such as a thermally curable epoxy or aerobicallycurable epoxy or moisture curable epoxy or UV curable epoxy or the like)is cured, the epoxy and the biased connectors ensure a substantiallystrong and secure contact of the connectors.

The biased contacts or connectors thus reduce the solder operations andmay reduce or substantially eliminate precise soldering operations andmay provide for solderless electrical connections of contacts/connectorsof the mirror assembly. For example, and with reference to FIG. 34, areflective element assembly 780 may include a reflector carrier or backplate 782 for attaching to a rear surface of a reflective element orcell 784 and a printed circuit board 786 for attaching to the back plate782 and making electrical contact between the circuit board 786 and backplate 782 when attached thereto. As shown in FIG. 34, back plate 782 mayinclude a spring clip or electrical contact 782 a and one or morealignment tabs or posts 782 b extending from a rear surface of the backplate. The circuit board 786 may include an electrical contact 786 a(which is electrically connected to circuitry on the circuit board) andopenings or apertures 786 b for receiving posts 782 b of back plate 782when circuit board 786 is attached to back plate 782. Thus, as thecircuit board 786 is pressed into engagement with back plate 782,electrical contact 786 a is pressed into engagement with electricalcontact 782 a and mechanically held in contact via retaining clips orthe like (not shown) that hold the circuit board to the back plate.

As shown in FIG. 34, one of the electrical contacts 782 a, 786 a iscoated or wiped with a conductive epoxy 788 (such as a quick setconductive epoxy material or the like), so that when the electricalcontacts are pressed together, there is a strong electrical connectionbetween the contacts that is augmented by the presence and curing of theconductive epoxy. The electrical contact 782 a at back plate 782 may bein electrical contact with a conductive pad or bus-bar at the rearsurface of the reflective element, such as a fourth surface conductivebus-bar of the types described in U.S. patent application Ser. No.11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451; and/orU.S. provisional application Ser. No. 60/644,903, filed Jan. 19, 2005;and Ser. No. 60/667,049, filed Mar. 31, 2005, which are herebyincorporated herein by reference. The conductive pad or bus-bar maycomprise any suitable material, such as a copper beryllium material or asilver plated nickel material or the like. Optionally, a metallic tab(such as a tab of the types described in U.S. provisional applicationSer. No. 60/644,903, filed Jan. 19, 2005; and Ser. No. 60/667,049, filedMar. 31, 2005, which are hereby incorporated herein by reference) may beprovided that allows for connection to a wire or lead, whereby the wireor lead is crimped to the tab, and then the mechanical connection islater augmented via soldering or via conductive epoxy. Optionally,aspects of the mirror assemblies described in U.S. patent applicationSer. No. 10/512,206, filed Oct. 22, 2004, now U.S. Pat. No. 7,110,156,which are hereby incorporated herein by reference, may be utilized.

The support element 750 (FIG. 25) thus may receive and support thereflective element 714 and may provide a substantially framelessreflective element assembly 710. The support element may substantiallyconceal the perimeter edges of the reflective element via the lipportion or small overhang portion. The support element may be molded tothe desired shape and dimensions for a particular reflective elementapplication, and the reflective element (of the substantiallycorresponding shape and slightly oversized dimensions) may be readilyinserted into the molded support element to form the reflective elementassembly. The reflective element may be inserted into the supportelement after the support element is molded and cooled or may beinserted into the support element when the support element is warm andpliable (such as soon after molding the support element and before themolded support element has cooled or after heating the molded and cooledsupport element to a desired elevated temperature to enhance thepliability of the molded support element), without affecting the scopeof the present invention. When inserted into the support element, thereflective element is retained therein via engagement with the backportion 754 and the lip portion 756 and the side wall portion 752 at theperimeter edge of the front substrate. The wall portions/lip of thesupport element thus contact only the front substrate and do not contactthe edge regions of the rear substrate (due to the oversized dimensionof the front substrate relative to the rear substrate and the overhangregions of the reflective element), and thus does not impart hoopstresses to the seal of the reflective element or cell as could occurshould the front substrate be offset/staggered to the rear substrate.

One advantage of the present invention is that the sidewalls and/or lipof the support element function to mask from view the cut edge andseamed edge sides of the front substrate, and so remove from direct viewany sparkle or chips or glass imperfections or the like at the frontviewable surface of the reflective element. Also, when cutting the frontsubstrate shape, cutting tolerances in dimensions (such as a cuttingtolerance of, for example, 0.015 inch or thereabouts) may occur. In thisregard, forming the support element via injection molding (such asdescribed below) may have advantages in that the injected molten resincan take up or accommodate any cutting tolerances of the front substrateinserted into the molding tool.

Although shown and described as being a substantially continuous panelalong and over the rear surface of the reflective element, it isenvisioned that the back portion of the support element may be partiallyor substantially open and thus may only partially cover the rear surfaceof the reflective element, such as around the perimeter regions of thereflective element, without affecting the scope of the presentinvention. Optionally, the back portion may be substantially continuousand may not include apertures or openings or the like, and thus maysubstantially or entirely cover the rear surface of the reflectiveelement, without affecting the scope of the present invention.

Optionally, and with reference to FIG. 26, a support element 750′ may bemolded around the perimeter regions and rear surface of the reflectiveelement 714. For example, the reflective element or cell may be placedin an injection molding tool or the like, and a plastic or polymericmaterial may be injected or molded around the reflective element.Preferably, a low pressure injection molding process, with a lowpressure mold material, such as reaction injection molding (RIM)urethane or suitable equivalent, or the like, may be used to mold thesupport element around the perimeter regions of the reflective element.In such applications, any tolerance variations in the dimensions of thefront and/or rear substrates of the reflective element may beaccommodated by the molded support element that is molded over theperimeter regions of the reflective element. The over molded supportelement thus may substantially fill in the overhang regions of thereflective element where the front substrate extends beyond or overhangsthe rear substrate, and does not include the notches or grooves to allowfor flexing of the support element. The electrical connection apertures768, 770 may be formed in the back portion 754′ of support element 750′or conductive posts or the like may be insert molded into the backportion 754′ and in electrical/conductive contact with the fourthsurface bus-bars 764, 766 as the support element is molded over andaround the reflective element. The support element 750′ may be otherwiseshaped substantially similar to the support element 750 discussed above,and may include the openings or apertures 762, 768, 770 in the backportion 754′ and the attachment elements 760′ at the back portion 754′,such that a detailed discussion of the support elements will not berepeated herein. The similar features of the reflective elements andsupport elements are referenced in FIG. 26 with similar referencenumbers as used in FIG. 25.

Because the support element may be integrally molded substantiallyaround the reflective element, the support element may seal andenvironmentally protect the reflective element within the supportelement. The overmolded support element may be substantially attached tothe reflective element and may adhere to or bond to the reflectiveelement as the molded material cures, so that the back portion may besubstantially attached to the rear surface of the reflective element.Optionally, enhanced adhesion may be achieved by priming the perimeteredges of the substrates and/or rear surface of the reflective element,such as a with an adhesion enhancing or adhesion promoting couplingagent or compound or primer or the like, such as by utilizing principlesdescribed in U.S. Pat. Nos. 6,298,606; 6,128,860; 5,966,874; 5,704,173and 5,551,197, which are hereby incorporated herein by reference. Suchadhesion-promoting compounds may include silanes, such as available fromDow Corning, or titanium or zirconium coupling agents such as availablefrom Kenrich Petrochemical, Inc., of Bayon, N.J., or equivalents.

As shown in FIG. 26, the overmolded support element 750′ may include thesmall perimeter lip portion 756′ that overlaps the perimeter edges ofthe front substrate of the reflective element and overlays the perimeteredge regions of the front surface of the front substrate. However,because the support element may be substantially adhered/attached to thereflective element by the molding process, the support element 750′ maynot include the lip portion. In such applications, the perimeter edge ofthe front substrate may, if desired, be finished or rounded to provide anon-sharp edge at the front of the reflective element.

Optionally, the support element 750, 750′ may be formed to include theback plate or attachment plate of the reflective element, such that theback portion and back/attachment plate are unitarily formed. Optionally,the attachment or socket for a ball member of a mounting structure orthe like may also be established at the unitary back portion andattachment plate of the support element. The attachment elements thusmay not be molded at the back portion, or other attachment elements maybe molded for attaching a circuit board or the like at the moldedattachment plate of the support element.

Optionally, the molded support element 750, 750′ may have or include orincorporate stiffening elements, such as stiffening ribs or plates orthe like, positioned thereon or insert molded therein, in order toprovide a stiffening function to the support element. Such stiffeningelements or plates or the like may provide enhanced structuralrobustness to limit or substantially preclude flexing and breaking ofthe reflective element if the reflective element is impacted. Such astiffening function is desirable since the reflective element issubstantially frameless, whereby an impact to the front of the mirrorassembly may be substantially absorbed by the reflective element insteadof a bezel portion of a mirror casing. Such a stiffening function maythus be desirable and may assist in meeting impact and/or bendingregulations/requirements, such as set forth in a French Bend test (suchas is known in the automotive mirror safety testing arts) or the like.For example, the French Bend test requires that the reflective elementwithstand bending when impacted or struck by a large ball member.Because prior art mirror assemblies include bezel portions, the ballmember (which is a large size relative to the width or height of thereflective element) often impacts the bezel portion and not thereflective element, such that the impact is substantially absorbed bythe bezel portion. Thus, the stiffening function of the support elementmay be desired to assist the substantially frameless reflective elementof the present invention in absorbing the impact and not over bending orflexing during such testing. Optionally, other elements, such as heatingelements and/or the like (such as heating elements of the typesdescribed in U.S. provisional applications, Ser. No. 60/644,903, filedJan. 19, 2005; and Ser. No. 60/667,049, filed Mar. 31, 2005, which arehereby incorporated herein by reference) may be insert molded in and/orattached to the back portion of the support element.

The support element of the present invention thus provides a supportfunction for the reflective element to substantially support and encasethe reflective element within the plastic or polymeric pocket of thesupport element. The support element may also provide a mountingfunction, such as via a unitary mounting plate or mounting structure orvia attachment elements for attaching to a mounting plate or structure.The support element may also provide a stiffening function viastiffening elements or via the material selected for the supportelement, in order to provide enhanced structural rigidity and strengthto the reflective element and support element assembly. The supportelement of the present invention provides such functions while alsoproviding a substantially frameless reflective element for asubstantially frameless mirror assembly. The reflective element andsupport element assembly may be readily installed in or at a mirrorcasing and/or mounting structure, with the electrical connectionsbetween the reflective element conductive coatings (and optionally aheater or heater pad at the rear surface of the reflective element) andthe associated circuitry and connections at a circuit board or backingplate or the like being made as the reflective element and supportelement assembly is attached to the backing plate or circuit board orthe like.

The support element of the present invention also provides an enhancedappearance to the reflective element assembly and mirror assembly. Thelip portion may slightly overlap or overlay the cut edge at theperimeter edge of the front substrate, and the sidewalls/structure ofthe support element may overlay the side edge (the thickness dimensionof the front substrate) of the reflective element and thus may cover orconceal any sparkling or chips that may be present on or at theperimeter edge so that any such sparkling or chips or imperfections ator on the perimeter region of the reflective element may not be readilyviewable by the driver or occupant of the vehicle. Also, it isenvisioned that the support element may be molded or formed to have adesired or selected color and/or texture and/or design/appearance, so asto provide a desired cosmetic appearance to the reflective element andto the mirror assembly. Also, the presence of the slight lip portionand/or the sidewall/side structure of the support element helpcamouflage and/or mask edge imperfections even from indirect view orangled view from the front of the mirror reflector due to the multiplereflections at the edge caused by the mirror reflector, and as outlinedin U.S. Pat. No. 5,066,112, which is hereby incorporated herein byreference.

In accordance with the present invention, a manufacturer of anelectro-optic cell or reflective element can ship from the manufacturingplant (or from an assembly point in the manufacturing plant or facility)an electro-optic or electrochromic cell (with or without electricalconnectors and the like) having raw edges to the assembly or moldingstation. At the assembly or molding stations, the cell may be insertedinto the support element or the support element may be molded over thecell to form a cell subassembly. The cell subassembly (which includesthe reflective element or cell and the support element) may be providedto an interior rearview mirror maker or manufacturer, where theappropriate or desired back plate or attachment plate or toggle platemay be attached to the back of the support element.

Preferably, the reflective element or cell subassembly is assembled intothe mirror casing/assembly by assembling along a common axis or z-axis,such as described in U.S. patent application Ser. No. 10/933,842, filedSep. 3, 2004, now U.S. Pat. No. 7,249,860, which is hereby incorporatedherein by reference. Preferably, the back plate and/or circuit boarddoes not have structure that limits the plate or board from moving alongthe common axis or z-axis and into engagement/contact with the supportelement. Desirably, a display element or device may be positioned on therear side of the circuit board and in alignment with a hole through thecircuit board so that the circuit board may be moved along the z-axisand into substantial engagement with the back surface of the supportelement with little structural elements between the circuit boardsubstrate and the back surface of the support element.

Therefore, the present invention provides a unitarily molded or formedmounting assembly, with the toggle portion and/or channel mount moldedover the ends of the mounting arm. The mounting arm may include a ballmember or partial ball member at one or both ends for pivotallyattaching the mounting arm to the toggle portion and/or the channelmount when the toggle portion and/or channel mount is/are molded overthe ball members of the mounting arm. The molded or pre-formed mountingarm may be inserted or loaded into a mold and the toggle portion andchannel mount may be molded over the ends of the mounting arm to formthe mounting assembly via a unitary molding process. The pivot jointsdefined by the ball members and overmolded portions may providedifferent frictional resistance to provide different threshold torquesfor pivoting the mirror assembly or mounting arm about the respectivepivot joints. For example, the mounting assembly may provide differentsurface conditions or different materials or the like to providedifferent torques at the pivot joints of the mounting assembly. Thepresent invention thus provides for in mold forming of a socket around aball member or ball members that is/are pre-formed and inserted into themold cavity. The polymeric socket and/or mounting base may be moldedover a metallic insert to provide the mounting structure and structuralintegrity at the base. The base may include an electrical element orcomponent, such as an accessory or sensor or circuitry or circuit boardor connector or the like, and may connect to a conductor that is moldedin and along the support or mounting arm.

Optionally, other components can be overmolded along with thosedescribed above, including, for example, a mirror housing or casing.Also, aspects of the present invention are applicable broadly. Forexample, a support arm with integrally molded wire harness such asdescribed above can be formed, and a mirror mount or base (and/or a backplate/toggle) can be attached thereto by other than overmolding (such asby mechanical attachment with spring-established torque at ball joints,such as is disclosed in U.S. Pat. Publication No. US2002/0088916, nowU.S. Pat. No. 6,877,709, incorporated above). By combining the metallicportions with an overmolded plastic portion, the present inventionprovides advantages of both materials, the rigidity of metal and theflexibility and resilience of plastic in a single component/part. Thepresent invention provides economical constructions and methods offabrication for double ball interior mirror assemblies with integratedwire management so that wires emanating from the vehicle roof area mayenter the interior mirror assembly (such as via a plug or socketconnector integrated into the mirror mount or base portion of theassembly), and then, hidden from view of a vehicle occupant, may passthrough the first ball joint (proximate to the location or attachment ofthe mirror mount or base to a mirror mounting button on the windshield),and then may pass through the mirror support arm, and then may passthrough the second ball joint (that allows the mirror housing or casingto pivot about the support arm), and thus may pass into the cavityformed by the mirror housing or casing, in order to supply electricalpower and signals to and from electronic components and circuitrydisposed within the head of the interior mirror assembly.

Optionally, and with reference to FIG. 27, a mirror assembly 810includes a reflective element assembly 814 that is received at leastpartially in a molding or casing or housing 816, which is mounted to aninterior portion of the vehicle via a mounting arrangement 812. Casing816 comprises a unitarily molded or formed casing that includes an outerrim or bezel portion 816 a for receiving and retaining reflectiveelement assembly 814 at casing 816. The reflective element assembly 814comprises an electro-optic reflective element assembly or cell, such asan electrochromic reflective element assembly or cell, and includes afront substrate 820 and a rear substrate 822, with an electro-opticmedium (not shown in FIG. 27) sandwiched therebetween, such as describedabove. The electro-optic reflective element assembly 814 may be readilyinstalled or received in the casing and retained therein via the outerrim portion 816 a, as discussed below.

Casing 816 includes outer rim portion 816 a, side walls 816 b and a rearwall 816 c that define a cavity therewithin. Rear wall 816 c may attachto or receive or may be molded over a ball stud or ball member 812 a ofmounting arrangement 812. For example, the ball stud 812 a may be insertmolded within a portion of rear wall 816 c to affix ball stud 812 a tocasing 816 via a plurality of tabs of ball stud 812 a that have thematerial of casing 816 molded over and around to retain andsubstantially secure the ball stud to the casing. The ball stud 812 amay be received within a mounting arm 812 b, which in turn may pivotallyreceive another ball member 812 c of a mounting base or channel mount812 d. The channel mount 812 d is attached to an interior surface of thevehicle to attach the mirror assembly to the vehicle. The mountingarrangement 812 includes a spring or biasing element 812 e for urgingthe ball members 812 a, 812 c outward relative to mounting arm 812 b toprovide the desired frictional resistance to pivotal movement at eachball member. The mounting arm and/or ball members may utilize aspects ofthe mounting arrangements described above.

Casing 816 includes a plurality of tabs or retaining clips 830 a andretaining or support posts 830 b for retaining a printed circuit board832 or other circuitry element within casing. The posts 830 a functionto space the circuit board 832 at the desired location from the rearwall 816 c, while the tabs 830 a snap or clip to the circuit board toretain the board or substrate at the desired location on the posts.Mirror assembly 810 also includes an electrical connector 834, such as amulti-pin connector for electrically connecting the circuit board andcircuitry of the mirror assembly to a wire harness or the like of thevehicle. The connector may protrude through rear wall 816 c so as to beaccessible at the rear of the mirror assembly for connection theretowhen the mirror assembly is installed in a vehicle.

Mirror casing 816 also includes a plurality of webs or support posts 836extending from rear wall 812 c and toward reflective element assembly814. Support posts 836 may include a tensioning or biasing element 838therein or therealong for engaging a rear surface 822 a of rearsubstrate 822 of reflective element 814 to urge the reflective elementforward or outward to maintain engagement of the front surface 820 a offront substrate 820 at a lip 816 d of outer rim portion 816 a of casing816. A foam element or anti-scatter element 840 may be disposed betweenthe rear surface 822 a of rear substrate 822 of reflective element 814and the printed circuit board 832 to support the reflective element atits generally central region. Optionally, the side walls 816 b of casing816 may include notches or grooves or regions of reduced thickness so asto enhance flexing of the side walls as the reflective element isinserted into the casing, such as grooves or channels that function in asimilar manner as the groove or notch portion 758 of support 750,discussed above with respect to FIG. 25. The side walls thus may flexoutwardly as the reflective element is inserted into the casing and thenmay flex back toward the initial orientation after the reflectiveelement is positioned inward of the bezel or rim portion 816 b, with therim portion covering a perimeter region of the front surface of thereflective element and substantially retaining the reflective elementwithin the casing.

Preferably, reflective element 814 comprises a non-offset reflectiveelement or a reflective element with the rear substrate smaller acrossat least one dimension so that the front substrate extends outwardlypast the edges of the rear substrate, such that the perimeter of thefront substrate defines the profile or footprint of the reflectiveelement. The profile is thus set by the relatively predictabledimensions of the front substrate only, and thus is substantiallyconsistent for a particular application, since variations oruncertainties in the degree of offset that may arise when the front andrear substrates are offset will thus not affect the profile of thereflective element. The present invention thus may be particularlysuited for exterior mirror applications and/or mirror applications witha “frameless” reflective element having a flush or near flush frontsubstrate to rear substrate alignment, such as having a recessed rearsubstrate (where the front substrate extends past the edges of the rearsubstrate to define overhang regions along the respective edge regions).The reflective element thus may be readily inserted into the casing andmay be substantially retained therein when positioned within the casingand with the outer rim portion overlapping the perimeter edge of thefront substrate and a perimeter portion of the front substrate.

Optionally, a photo sensor or glare sensor 842 may be positioned at thecircuit board to detect or sense light or glare through the reflectiveelement, while a display element or indicator 844 may be positioned atthe circuit board to emit or transmit light or display informationthrough the reflective element for viewing by the driver of the vehicle.The reflective element may have a window formed in its reflectivecoating or may comprise a transflective reflective element such as thetypes described below. The sensor and/or display element may bepositioned remote from the foam element or may be positioned behind thefoam element, whereby the foam element may have a correspondingpassageway or opening formed therethrough to provide a light conduitbetween the reflective element and the sensor or display element.

The unitary casing 816 of the present invention thus provides enhancedassembly of the mirror assembly. The ball stud may be insert moldedwithin the rear wall of the casing to provide a unitary construction ofthe casing and ball member. The printed circuit board (or othercircuitry element or elements) may be readily inserted into the casingand snapped in place within the cavity of the casing, and the reflectiveelement may be inserted into the casing and snapped in place via the lipor tab or perimeter rim portion of the casing. When the reflectiveelement is received within the casing, the biasing elements urge thereflective element outward and into engagement with the perimeter tabsor lips of the perimeter rim portion to substantially retain thereflective element in place within the unitary casing. The foam element(or similar or other resilient member, such as a rubber pad or a similarresilient, spring-like member, that urges the reflective element intotight engagement with the rim portion of the mirror casing) may bepositioned at the rear surface of the reflective element or at thecircuit board or element prior to assembly of the reflective element tothe casing. The foam or similar resilient element may be adhesivelyfaced, such as via a pressure sensitive adhesive, so as to provide ananti-scatter feature when it urges to and adheres to the rear of thereflective element, and may reduce vibration of the reflective element.The mirror assembly thus may be readily assembled via insertion of thecomponents into the unitary casing, and without having to separatelysecure or retain a bezel portion to a rear casing portion.

Optionally, the circuit board or circuitry or casing or mirror assemblymay include electrical contacts for contacting contacts at the rearsurface of the reflective element or cell as the cell is inserted intoand retained in the casing, so that the electrical contacts to thereflective element or cell (such as to power the conductive coatings ofthe cell or to power a heater pad or the like at the cell) are made asthe reflective element is inserted or loaded into the casing of aninterior mirror or a back plate of an exterior electrochromicsubassembly. For example, electrical contacts may extend outwardly fromthe circuit board or element when the circuit board or element is loadedinto the casing to establish electrical conductivity between thecircuitry of the circuit element and the reflective element. Optionally,the electrical contacts may be insert molded in the casing side walls orin webs or tabs of the casing so as to make the appropriate electricalcontacts and connections to the contacts at the rear surface of thereflective element as the reflective element is loaded into the casing.The insert molded electrical contacts may connect to the contacts at thereflective element and may contact and connect to other electricalcircuitry, such as to contacts on the circuit board or element as thecircuit board or element is loaded into the casing, or such as tocontacts or connectors of a vehicle wire harness or the like at the rearof the casing.

The electrical contacts of the circuit board or element or casing orcircuitry of the mirror assembly may be biased or spring-loaded orresiliently urged so as to urge against the contacts at the rear surfaceof the reflective element to substantially ensure firm and reliableelectrical connection between the contacts when the reflective elementis inserted or loaded or pressed into the casing. The contacts thusprovide a tight fit against the contacts of the rear surface of thereflective element by urging against the rear surface of the reflectiveelement while the outer rim portion of the casing limits outwardmovement of the reflective element, such that the reflective element istightly received between the outer rim or bezel portion of the casingand the posts of the casing and the electrical contacts of the circuitelement and/or casing. The contacts may provide power and ground to theconductive coatings of the reflective element and/or may provide powerand ground to a heater pad at the rear surface of the rear substrate(such as for exterior mirror applications) and/or may provide powerand/or ground to other accessories or circuitry at the reflectiveelement.

Therefore, the mirror assembly of the present invention may be readilyassembled with the electrical connections being made during thesnap-together assembly processes. The casing may be molded of apolymeric material (such as polypropylene or the like), and may beconfigured or molded or formed to receive and retain a printed circuitboard or circuit substrate or element or circuitry therein. The circuitelement may be inserted into the casing and snapped to the snap claspsor the like formed within the cavity of the casing. When inserted orloaded into the casing, the circuit element may connect to or mayinclude a connector (such as a multi-pin connector or the like) that maybe positioned at or through an opening in the rear wall of the casingfor electrical connection to a vehicle wire harness or the like at therear of the mirror assembly. Optionally, the circuit board or elementmay electrically contact one or more contacts that are insert moldedwithin the casing to establish electrical connection to other circuitryor connectors of the casing and mirror assembly.

The reflective element may then be readily inserted into the casing,whereby the side walls of the casing may flex or spring outwardly toallow for insertion of the reflective element into the casing. The sidewalls may flex or spring toward their initial orientation when thereflective element is loaded into the casing, so that the outer rimportion of the casing engages the perimeter region of the frontsubstrate of the reflective element to substantially retain thereflective element within the casing. As the reflective element isinserted or loaded into the casing, electrical contacts on the circuitelement (or on or in the casing) may contact corresponding orappropriate contacts at the rear surface of the reflective element toestablish electrical connection and conductivity between the circuitryof the circuit element (or casing or mirror assembly) and circuitry ofthe reflective element. The electrical contacts may urge toward andagainst the contacts on the rear surface of the reflective element whenthe reflective element is received and snapped in the casing so as tomaintain firm and reliable electrical contact with the contacts at therear surface of the reflective element. The present invention thusallows for loading of circuitry and accessories and the like within thecasing and then loading of the reflective element into the casingwhereby electrical connections may be made during the loading orsnapping assembly processes.

Optionally, the mirror assembly of the present invention may include oneor more user actuatable inputs or input devices or human machineinterfaces. For example, the inputs or user interfaces may includebuttons, such as are described in U.S. Pat. No. 6,501,387, which ishereby incorporated herein by reference, or that include touch/proximitysensors such as are disclosed in U.S. Pat. Nos. 6,001,486; 6,310,611;6,320,282 and 6,627,918, and U.S. patent application Ser. No.09/817,874, filed Mar. 26, 2001, now U.S. Pat. No. 7,224,324, and PCTApplication No. PCT/US03/40611, filed Dec. 19, 2003, which are herebyincorporated herein by reference, or that include other types of buttonsor switches, such as those described in U.S. patent application Ser. No.11/029,695, filed Jan. 5, 2005, now U.S. Pat. No. 7,253,723; and/or Ser.No. 11/140,396, filed May 27, 2005, now U.S. Pat. No. 7,360,932; and/orU.S. provisional application Ser. No. 60/690,401, filed Jun. 14, 2005;Ser. No. 60/556,259, filed Mar. 25, 2004; Ser. No. 60/553,517, filedMar. 16, 2004; and/or Ser. No. 60/535,559, filed Jan. 9, 2004; and/orPCT Application No. PCT/US2004/015424, filed May 18, 2004, which arehereby incorporated herein by reference, or that include fabric-madeposition detectors, such as are disclosed in U.S. Pat. Nos. 6,504,531;6,501,465; 6,492,980; 6,452,479; 6,437,258 and 6,369,804, which arehereby incorporated herein by reference. The manual inputs or useractuatable inputs or actuators may control or adjust oractivate/deactivate one or more accessories or elements or features. Fortouch sensitive inputs or applications or switches, the mirror assemblyor accessory module or input may, when activated, provide a positivefeedback (such as activation of an illumination source or the like, orsuch as via an audible signal, such as a chime or the like, or a tactileor haptic signal, or a rumble device or signal or the like) to the userso that the user is made aware that the input was successfullyactivated.

Optionally, two or more inputs or buttons may be positioned adjacent toor near to one another, such as at the mirror assembly or accessorymodule or windshield electronics module. The buttons or switches orinputs may be selectively/individually activated by a user toactivate/deactivate/control/adjust the corresponding accessory or deviceor feature/function. The control or mirror assembly or accessory moduleor windshield electronics module may include circuitry or logic thatfunctions to desensitize one of the buttons or inputs when an adjacentbutton or input is activated, in order to limit or substantiallypreclude inadvertent activation of both buttons or inputs. For example,three buttons, such as for a garage door opening system of the vehicle,may be positioned adjacent to or near to one another. If one of thebuttons is activated, such as by touching of the button with a person'sfinger or by close proximity of a person's finger to the button, thenthe logic or control may desensitize the other two buttons to limitinadvertent activation of the other buttons when the function associatedwith the first button activated was desired. Optionally, if two buttonsor inputs are substantially simultaneously activated, the control orlogic may function to desensitize the third button or input to limit orsubstantially preclude inadvertent activation of the third button orinput. The non-activated input or inputs may be desensitized for aperiod of time following the activation of the first input or inputs,and then re-sensitized so that a user may subsequently activate theother input or inputs. Note, sensitivity of such a system may be set soas to be responsive to a gloved finger or the like.

Optionally, a reflective optical sensor capable of operating in brightsunlight and available from Vishay Intertechnology, Inc. of Malvern,Pa., may be used in conjunction with the interior mirror assembliesand/or windshield electronics modules/accessory modules of the presentinvention. For example, a TCND3000 surface-mount optical sensor, whichintegrates touch and proximity functions and operates in conjunctionwith an integrated circuit (E909.01) built on ELMOS Semiconductor'sHALIOS® (High Ambient Light Independent Optical System) technology(available from ELMOS Semiconductor AG of Dortmund, Germany) to providereliable operation in very bright sunlight up to 200 kLux, may be usedas an economical alternative to mechanical switches.

The TCND3000 series device is highly integrated and combines aninfra-red (IR) emitter as the source for the touch/proximity signal,another for compensation for ambient light, and a photo diode as thereceiver for the touch/proximity signal to allow (working with theelectrical signal evaluation system provided by the ELMOS E909.01 IC)contact-free detection of movement through a translucent surface, andenabling proximity detection at a distance of about 2 cm and touchdetection at a distance at a distance of about 1 cm from the sensorsurface. As a result, the sensor may be contained within a clearprotective or decorative casing without loss of sensitivity. Theself-adjusting system compensates for environmental disturbances such asambient light, aging of optical components, and surface impurities orscratches. Such TCND3000 sensors measure about 5 mm by about 2.6 mm witha height profile of about 3 mm. These RoHS (restriction of hazardoussubstances)-compliant devices are available in a lead (Pb)-free,surface-mount-style package constructed on PCB mold technology. Eachfeatures a 5 Volt operating voltage, a ±20 degree angle ofhalf-sensitivity, an 870-nm operating wavelength, and an operatingtemperature range of −40 degrees Celsius to +85 degrees Celsius. Suchdevices are designed for IR reflow soldering with a peak temperature of260 degrees Celsius and therefore are suitable for lead-free solderprocesses.

Optionally, the mirror assembly may include one or more accessoriesincorporated onto the printed circuit board or positioned elsewhere ator within the mirror casing or at or within an accessory module orwindshield electronics module associated with the interior rearviewmirror assembly. For example, the accessory or accessories may includeone or more electrical or electronic devices or accessories, such asantennas, including global positioning system (GPS) or cellular phoneantennas, such as disclosed in U.S. Pat. No. 5,971,552, a communicationmodule, such as disclosed in U.S. Pat. No. 5,798,688, a blind spot orobject detection system, such as imaging or detection systems of thetypes disclosed in U.S. Pat. Nos. 5,929,786 and/or 5,786,772, and/orU.S. patent application Ser. No. 10/427,051, filed Apr. 30, 2003, nowU.S. Pat. No. 7,038,577, and/or U.S. provisional applications, Ser. No.60/628,709, filed Nov. 17, 2004; Ser. No. 60/614,644, filed Sep. 30,2004; Ser. No. 60/618,686, filed Oct. 14, 2004; Ser. No. 60/638,687,filed Dec. 23, 2004, transmitters and/or receivers, such as a garagedoor opener or the like, a digital network, such as described in U.S.Pat. No. 5,798,575, a high/low headlamp controller, such as disclosed inU.S. Pat. Nos. 5,796,094 and/or 5,715,093; and/or U.S. provisionalapplications, Ser. No. 60/607,963, filed Sep. 8, 2004; and Ser. No.60/562,480, filed Apr. 15, 2004; and/or U.S. patent application Ser. No.11/105,757, filed Apr. 14, 2005, a memory mirror system, such asdisclosed in U.S. Pat. No. 5,796,176, a hands-free phone attachment, avideo device for internal cabin surveillance and/or video telephonefunction, such as disclosed in U.S. Pat. Nos. 5,760,962 and/or5,877,897; and/or PCT Application No. PCT/US03/40611, filed Dec. 19,2003, and/or U.S. provisional application Ser. No. 60/630,061, filedNov. 22, 2004; and Ser. No. 60/667,048, filed Mar. 31, 2005, a remotekeyless entry receiver or system or circuitry and/or a universal garagedoor opening system or circuitry (such as the types disclosed in U.S.Pat. Nos. 6,396,408; 6,362,771; 5,798,688 and 5,479,155, and/or U.S.patent application Ser. No. 10/770,736, filed Feb. 3, 2004, now U.S.Pat. No. 7,023,322), lights, such as map reading lights or one or moreother lights or illumination sources, such as disclosed in U.S. Pat.Nos. 6,690,268; 5,938,321; 5,813,745; 5,820,245; 5,673,994; 5,649,756;5,178,448; 5,671,996; 4,646,210; 4,733,336; 4,807,096; 6,042,253 and/or5,669,698, and/or U.S. patent application Ser. No. 10/054,633, filedJan. 22, 2002, now U.S. Pat. No. 7,195,381, microphones, such asdisclosed in U.S. Pat. Nos. 6,717,524; 6,650,233; 6,243,003; 6,278,377and/or 6,420,975, and/or PCT Application No. PCT/US03/30877, filed Oct.1, 2003, speakers, a compass or compass system, such as disclosed inU.S. Pat. Nos. 5,924,212; 4,862,594; 4,937,945; 5,131,154; 5,255,442and/or 5,632,092, and/or U.S. patent application Ser. No. 10/456,599,filed Jun. 6, 2003, now U.S. Pat. No. 7,004,593; and/or U.S. provisionalapplication Ser. No. 60/636,931, filed Dec. 17, 2004, a navigationsystem, such as described in U.S. Pat. No. 6,477,464, and U.S. patentapplication Ser. No. 10/456,599, filed Jun. 6, 2003, now U.S. Pat. No.7,004,593; Ser. No. 10/287,178, filed Nov. 4, 2002, now U.S. Pat. No.6,678,614; Ser. No. 10/645,762, filed Aug. 20, 2003, now U.S. Pat. No.7,167,796; and Ser. No. 10/422,378, filed Apr. 24, 2003, now U.S. Pat.No. 6,946,978; and/or PCT Application No. PCT/US03/40611, filed Dec. 19,2003, a tire pressure monitoring system, such as the types disclosed inU.S. Pat. Nos. 6,294,989; 6,445,287 and/or 6,472,979, and U.S.provisional application Ser. No. 60/611,796, filed Sep. 21, 2004, a seatoccupancy detector, a vehicle occupancy detector, such as the typedescribed in U.S. provisional application Ser. No. 60/630,364, filedNov. 22, 2004, a trip computer, a telematics system, such as an ONSTAR®system or the like, and/or any other desired accessory or system or thelike (with all of the above-referenced patents and patent applicationsand PCT applications and provisional applications being commonlyassigned, and with the disclosures of all of the above referencedpatents and patent applications and PCT applications and provisionalapplications being hereby incorporated herein by reference in theirentireties).

The accessory or accessories may be positioned at or within the mirrorcasing and may be included on or integrated in the printed circuit boardpositioned within the mirror casing, such as along a rear surface of thereflective element or elsewhere within a cavity defined by the casing,without affecting the scope of the present invention. The useractuatable inputs described above may be actuatable to control and/oradjust the accessories of the mirror assembly/system and/or an overheadconsole and/or an accessory module/windshield electronics module and/orthe vehicle. The connection or link between the controls and the systemsor accessories may be provided via vehicle electronic or communicationsystems and the like, and may be connected via various protocols ornodes, such as Bluetooth™, SCP, UBP, J1850, CAN J2284, Fire Wire 1394,MOST, LIN, FlexRay™, Byte Flight and/or the like, or other vehicle-basedor in-vehicle communication links or systems (such as WIFI and/or IRDA)and/or the like, depending on the particular application of themirror/accessory system and the vehicle. Optionally, the connections orlinks may be provided via wireless connectivity or links, such as via awireless communication network or system, such as described in U.S.patent application Ser. No. 10/456,599, filed Jun. 6, 2003, now U.S.Pat. No. 7,004,593, which is hereby incorporated herein by reference,without affecting the scope of the present invention.

Optionally, a variety of display types or screens can be utilized inconjunction with an interior rearview mirror assembly or windshieldelectronics module/accessory module of the present invention. Forexample, the mirror assembly or module may include or be associated withdisplay elements, such as described in U.S. Pat. Nos. 6,329,925 and6,501,387, which are hereby incorporated herein by reference, or such asa display on demand type of display, such as of the types disclosed incommonly assigned U.S. Pat. Nos. 6,690,268; 5,668,663 and 5,724,187,and/or in U.S. patent application Ser. No. 10/054,633, filed Jan. 22,2002, now U.S. Pat. No. 7,195,381, and/or in PCT Application No.PCT/US03/29776, filed Sep. 19, 2003, and U.S. provisional applicationSer. No. 60/412,275, filed Sep. 20, 2002; Ser. No. 60/424,116, filedNov. 5, 2002; and Ser. No. 60/489,816, filed Jul. 24, 2003, which areall hereby incorporated herein by reference. The display element may beany type of display element, such as a vacuum fluorescent (VF) displayelement, a light emitting diode (LED) display element, such as anorganic light emitting diode (OLED) or an inorganic light emittingdiode, an electroluminescent (EL) display element, a liquid crystaldisplay (LCD) element, a video screen display element or the like, andmay be operable to display various information (as discrete characters,icons or the like, or in a multi-pixel manner) to the driver of thevehicle, such as passenger side inflatable restraint (PSIR) information,tire pressure status, and/or the like. The mirror assembly and/ordisplay may utilize aspects described in U.S. patent application Ser.No. 10/956,749, filed Oct. 1, 2004, now U.S. Pat. No. 7,446,924, and/orSer. No. 10/993,302, filed Nov. 19, 2004, now U.S. Pat. No. 7,338,177,and/or PCT Application No. PCT/US03/29776, filed Sep. 19, 2003; PCTApplication No. PCT/US03/35381, filed Nov. 5, 2003, and U.S. provisionalapplication Ser. No. 60/490,111, filed Jul. 25, 2003; and Ser. No.60/423,903, filed Nov. 5, 2002; and/or PCT Application No.PCT/US03/40611, filed Dec. 19, 2003, which are all hereby incorporatedherein by reference. Such display elements, such as a high intensityOLED or the like, may emit light with a high intensity through thecoatings of the reflective element for a display on demand (DOD)transflective type of display. The thicknesses and materials of thecoatings on the substrates, such as on the third surface of thereflective element assembly, may be selected to provide a desired coloror tint to the mirror reflective element, such as a blue coloredreflector, such as is known in the art and such as described in U.S.Pat. Nos. 5,910,854 and 6,420,036, and in PCT Application No.PCT/US03/29776, filed Sep. 9, 2003, which are all hereby incorporatedherein by reference. Such display devices may transmit the displayinformation or illumination through a transflective, third surfacereflective element assembly, such as described in U.S. Pat. Nos.5,668,663; 5,724,187 and 6,690,268, and/or in U.S. patent applicationSer. No. 10/054,633, filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381,and/or in PCT Application No. PCT/US03/29776, filed Sep. 19, 2003, whichare all hereby incorporated herein by reference.

Although such transflective reflective element assemblies are capable oftransmitting the illumination or display information through theassembly, it is sometimes desirable to provide a window in the metallicreflective coating through which the display information or illuminationmay be transmitted. Typically, such windows in the reflective coating oftransflective reflective element assemblies are desirable for a glaresensor (such as a photo sensor or the like, such as a glare sensorand/or an ambient light sensor and electrochromic automatic dimmingcircuitry described in U.S. Pat. Nos. 6,447,124; 4,793,690 and5,193,029, and U.S. patent application Ser. No. 10/456,599, filed Jun.6, 2003, now U.S. Pat. No. 7,004,593, which are all hereby incorporatedherein by reference) or the like to be positioned at, in order to allowsubstantial transmission of light from the rear of the mirror assemblyor vehicle through the reflective element assembly to the glare sensorpositioned within the mirror assembly.

Optionally, for example, the display or display element or displaydevice may utilize any of the liquid crystal type display or videoscreens (such as the types disclosed in PCT Application No.PCT/US03/40611, filed Dec. 19, 2003, and/or U.S. provisionalapplications, Ser. No. 60/630,061, filed Nov. 22, 2004; and Ser. No.60/667,048, filed Mar. 31, 2005, which are hereby incorporated herein byreference). Also, a microdisplay (such as is available from MicroVisionInc. of Bothell, Wash.), in which a single scanner is used to directmultiple light beams simultaneously into separate zones of an image soas to deliver a bright, high resolution, image over a wide field ofview, can be used. Such a microdisplay may utilize conventional surfaceemitting or other types of light emitting diodes (LEDs) as light sourcesto provide an economical display with sharp resolution and high imagebrightness. For example, multiple red, green and blue LEDs or red, blueand green laser diodes can be used to write several million red, green,and blue spots that integrate to form a single high-fidelity image in amega pixel display image. Such scanning display technologies can utilizea biaxial microelectromechanical scanner (MEMS) and otherdisplay/mechanical and electronic devices, such as are disclosed in U.S.Pat. Nos. 6,714,331; 6,795,221 and 6,762,867, which are herebyincorporated herein by reference, and can provide increased spatialresolution. Such displays can deliver an image with a full 30-degreehorizontal field of view or more. Such a microdisplay/MEMS device can,for example, be placed in the mirror housing behind the mirrorreflective element in an interior (or exterior) mirror assembly suchthat the image is projected onto the rear of the mirror reflectiveelement, such as is disclosed in U.S. patent application Ser. No.10/225,851, filed Aug. 22, 2002, now U.S. Pat. No. 6,847,487; and/orSer. No. 11/105,757, filed Apr. 14, 2005; and/or U.S. provisionalapplication Ser. No. 60/607,963, filed Sep. 8, 2004, which are herebyincorporated herein by reference.

If the mirror reflector of the mirror element is of the transflective(substantially reflective and at least partially transmitting to light)type, the driver or other occupant in the interior cabin of the vehiclecan view the image (being back-projected onto the rear of the mirrorreflective element) by viewing the mirror reflective element. This isbecause the front surface of the reflective element will typicallyreflect about 4 percent of the light incident on the reflective elementtoward the driver of the vehicle. Thus, if the display illumination(projected through the reflective element from behind the reflectiveelement and within the mirror casing) does not dominate or distinguishover the reflectance off of the front surface of the mirror reflectiveelement, the display illumination and information may appear washed outdue to the reflected image that is reflecting off of the front surfaceof the reflective element. Such washout may be particularly noticeableduring high ambient lighting or daytime lighting conditions. Becausesuch back-projected microdisplays can have a very high image brightness(due to use of very high brightness LEDs, preferably organic LEDs(OLEDs), or lasers as illuminators), image wash-out during driving underhigh ambient lighting conditions (such as on a sunny day) is reducedusing such scanning image microdisplay technology compared to use, forexample, of TFT LCD displays.

Optionally, such microdisplays or TFT LCD displays or the like mayincorporate a cooling device to reduce the temperature surrounding thedevice to provide enhanced performance of the device in high ambienttemperature conditions. Typically, such LCD screens and the like may beselected to perform within a specified temperature range. If a greateroperating temperature is desired, a display device that is capable ofoperating at the higher temperatures may be selected, typically at acost premium for the greater operating range. In some situations, it maybe cost effective to utilize a lower range or lower temperature displaydevice and utilize a heating and/or cooling device at or near orattached to the display device (such as to a rear surface of the LCDdisplay) to heat and/or cool the display device when the temperature atthe display device is below or above the range of the display device.For example, a thermoelectric module, such as a Peltier device, may beutilized. Such thermoelectric modules are typically small solid-statedevices that function as heat pumps. The module may comprise a sandwichformed by two ceramic plates with an array of small Bismuth Telluridecubes (“couples”) or the like in between. When a current is applied tothe module, heat may be moved from one side of the device to theother—where it may be dissipated or removed with a heat sink or thelike. The “cold” side may be used to cool the display device. If thecurrent is reversed, such thermoelectric modules may perform a heatingfunction. Such a Peltier device thus may be positioned in direct contactwith the rear of the LCD screen so that the Peltier device can thermallycool or heat the LCD screen by conduction of heat to the screen orextraction of heat from the screen. The Peltier device thus may providerapid heating or cooling of the display device so that the temperatureat the display device is within the desired or appropriate range.

Also, such MEMS technology can be used in a heads-up-display (HUD)system, such as the MicroHUD™ head-up display system available fromMicroVision Inc. of Bothell, Wash. (and such as described in U.S. patentapplication Ser. No. 11/029,695, filed Jan. 5, 2005, now U.S. Pat. No.7,253,723, which is hereby incorporated herein by reference). Thisprovides a compact heads-up display capable of meeting specific size andperformance specifications. For example, MicroVision's MicroHUD™combines a MEMS-based micro display with an optical package of lensesand mirrors to achieve a compact high-performance HUD module thatreflects a virtual image off the windscreen that appears to the driverto be close to the front of the car. This laser-scanning display canoutperform many miniature flat panel LCD display screens because it canbe clearly viewed in the brightest conditions and also dimmed to thevery low brightness levels required for safe night-time driving.

The high-resolution MicroHUD™ display may be completely reconfigurable,enabling virtually any content to be displayed, including video oranimated icons and graphics. Advantageously, such a MicroHUD™ displayunit may be included at or within an interior rearview mirror assemblyor a windshield electronics module/accessory module so as to project itsimage therefrom onto the inner surface of the windshield. This uniquepackaging of a HUD or projection image displayer into an interiorrearview mirror assembly or a windshield electronics module/accessorymodule has advantages over conventional placement of such HUD projectorsinto the dashboard of the vehicle. These advantages include that the HUDimage projector need not find space in an already crowded dashboard(where, for example, a center information cluster may want space orwhere HVAC ducts/components may run). Also, incorporation of the HUDprojector in the likes of the mounting portion of the interior mirrorassembly or into a windshield electronics module/accessory module canallow a HUD display to be provided more readily as an optional accessoryfor the vehicle or as a dealership option or aftermarket device. Avariety of images (such as, for example, iconistic or graphical or videoor textural or alphanumerical or numerical or the like) can bedisplayed, such as information from a side object/blind spot monitoringsystem and/or alert system and/or display device or system, such as thetypes described in U.S. Pat. No. 5,929,786, and/or U.S. patentapplication Ser. No. 10/427,051, filed Apr. 30, 2003, now U.S. Pat. No.7,038,577; and/or Ser. No. 10/209,173, filed Jul. 31, 2002, now U.S.Pat. No. 6,882,287, and/or U.S. provisional applications, Ser. No.60/638,687, filed Dec. 23, 2004; Ser. No. 60/696,953, filed Jul. 6,2005; and/or Ser. No. 60/171,093, filed Sep. 14, 2005, which are allhereby incorporated herein by reference.

As disclosed in U.S. patent application Ser. No. 10/209,173, filed Jul.31, 2002, now U.S. Pat. No. 6,882,287, incorporated above, a controllermay be provided, such as a microprocessor including a digital signalprocessor microcomputer of CPU speed at least about 5 MIPS, morepreferably at least about 12 MIPS and most preferably at least about 30MIPS, that processes inputs from multiple cameras and other sensors.

A control may comprise a central video processor module such as isdisclosed in provisional patent application Ser. No. 60/309,023, filedJul. 31, 2001. Such video processor module operates to receive multipleimage outputs from vehicle-mounted cameras, such as disclosed in patentapplication Ser. No. 09/793,002, filed Feb. 26, 2001, now U.S. Pat. No.6,690,268, and integrates these in a central processing module to allowreaction to the local vehicle environment. Optionally, and whenbandwidth limitations exist that limit the ability to send raw imagedata, particularly high-resolution images, from a remote camera to acentral processing unit across robust transmission means, such as afiber-optic cable or a high-density wireless link, distributedprocessing can occur, at least local to some of the image capturesensors. In such an at least partial distributed processing environment,the local processors are adapted to preprocess images captured by thelocal camera or cameras and any other device such as a Doppler radarsensor viewing a blind spot in an adjacent side lane and to format thispreprocessed data into a standard format and transmit this standardformatted data. The data can be transmitted via a wired network or awireless network or over a vehicle bus system, such as a CAN bus and/ora LIN bus, or the like, to the central processor for effective,centralized mapping and combination of the total local environmentaround the vehicle. This provides the driver with a display of what ishappening in both the right and the left side lanes, and in the lanethat the host vehicle is itself traveling in.

In this regard, the vehicle can be provided with a dedicated bus andcentral processor, as described above, for providing a vehicleenvironment awareness, which can be both internal such as might beprovided by interior cabin or trunk monitors/sensors that determineoccupant presence, head position and/or movement, eye movement, air bagdeployment, microphone aiming, seat positioning, air conditioning and/orheating targeting, audio controls, and the like, or can be external tothe vehicle such as in blind spot detecting or lane change detecting. Anautomatic environment awareness function may be provided that comprisesautomatic gathering of sensor-derived data collection and transmissionin a standard format via a vehicle bus network, said data including datarelating to the vehicle environment such as the exterior environment,for example, the presence of rear-approaching traffic in side and rearlanes to the host vehicle as captured by rear-facing CMOS or CCD camerason the side of the host vehicle, such as included in a side view mirrorassembly on either or both sides of the host vehicle and/or as detectedby a rear lane/side lane-viewing Doppler radar sensor, and preferablyincludes processing in a central video processing unit.

Outputs from video and non-video sensors can be fused, such as, forexample, a CMOS video camera sensor and a Doppler radar sensor, to allowall-weather and visibility side object detection. Fusion of outputs fromvideo and non-video sensors, such as, for example, a CMOS video camerasensor and a Doppler radar sensor, can occur to allow all-weather andvisibility side object detection.

Collision avoidance functionality can optionally be achieved using aforward-facing camera. For example, should the forward-looking cameradetect an oncoming car likely to collide with the vehicle equipped withthe present invention, or if another vehicle tries to pull in front ofit, the system of the present invention can issue a warning (visualand/or audible) to one or both drivers involved. Such warning can beflash headlights and/or sound car horn. Similarly, the system can detectthat the driver of the vehicle equipped with the present invention isfailing to recognize a stop sign and/or a signal light, or some otherwarning sign and the driver can be warned visually, such as with awarning light at the interior mirror in the vehicle cabin, or audibly,such as via a warning beeper, or tactilely, such as via arumble/vibration transducer that vibrates the steering wheel to alertthe driver of a potential hazard.

Also, the vehicle can be provided on its front fender or elsewhere atthe front of the vehicle with a side-looking camera as an image-baseddetector operable to warn the driver when he/she is making a left turnacross lanes of traffic coming from his/her left (left-side warning) andthen again when he/she is about to enter traffic lanes with trafficcoming from his right (right-side warning).

As disclosed in U.S. patent application Ser. No. 10/427,051, filed Apr.30, 2003, now U.S. Pat. No. 7,038,577, incorporated above, an imagingsystem for a vehicle and useful in this present invention comprises animaging array sensor having a plurality of photo-sensing or accumulatingor light sensing pixels, and a control responsive to the imaging arraysensor. The imaging array sensor is positioned at the vehicle andoperable to capture an image of a scene occurring exteriorly of thevehicle. The control is operable to process the captured image, whichcomprises an image data set representative of the exterior scene. Thecontrol is operable to apply an edge detection algorithm to the imagecaptured by the imaging array sensor to detect edges or objects presentexteriorly of the vehicle. The control may be operable to determinewhether the detected edges or objects are indicative of a significantobject or object of interest. The control is operable to process areduced data set or subset of the image data set, which isrepresentative of a target zone or area of the exterior scene, more thanother image data representative of areas of the exterior scene which areoutside of the target zone. The control thus may process image data ofthe reduced data set or subset, such as by applying an edge detectionalgorithm to the reduced data set, and substantially discount or limitprocessing of the other image data which is outside of the reduced dataset or subset of the image or of the target zone of the exterior scene.

The control may be operable to adjust the reduced data set or subset andthe corresponding target zone in response to various thresholdcriterion. The control may be operable to adjust the reduced data set ortarget zone in response to a distance to a detected edge or object. Thecontrol may approximate a distance to a portion of a detected edge orobject in response to a location of the pixel or pixels capturing theportion in the captured image. The pixel location may be determinedrelative to a target pixel which may be directed generally at thehorizon and along the direction of travel of the vehicle. For example,the control may be operable to approximate the distance using sphericaltrigonometry in response to a pixel size, pixel resolution and field ofview of the imaging array sensor. The control may access an informationarray which provides a calculated distance for each pixel within thereduced data set or target zone to approximate the distance to theportion of the detected edge or object.

In order to determine if a detected edge or detected edges is/are partof or indicative of a vehicle, the control may be operable to determineif the detected edge or edges is/are associated with an ellipse orpartial ellipse, since the ellipse or partial ellipse may be indicativeof a tire of a vehicle near the equipped vehicle, such as a vehicle in alane adjacent to the equipped vehicle. The control may also be operableto track one or more of the detected edges between subsequent framescaptured by the imaging array sensor to classify and/or identify theobject or objects associated with the detected edge or edges.

The object detection system or imaging system may comprise a lane changeassist system operable to detect vehicles or objects of interestsidewardly of the vehicle. Optionally, the control may be incommunication with a forward facing imaging system. The forward facingimaging system may communicate at least one of oncoming trafficinformation, leading traffic information and lane marking information tothe control of the lane change assist system to assist the lane changeassist system in readily identifying vehicles at the side of the subjectvehicle or adjusting a reduced data set or an area or zone of interestwithin the captured image. The control may be operable to adjust thereduced data set or target zone in response to the forward facingimaging system.

Optionally, the object detection system or imaging system may comprise aforward facing imaging system, such as a lane departure warning system.The lane departure warning system may provide a warning or alert signalto the driver of the vehicle in response to a detection of the vehicledrifting or leaving its occupied lane.

It is further envisioned that many aspects of the present invention aresuitable for use in other vehicle vision or imaging systems, such asother side object detection systems, forward facing vision systems, suchas lane departure warning systems, forward park aid systems or the like,rearward facing vision systems, such as back up aid systems or rearwardpark aid systems or the like, or panoramic vision systems and/or thelike.

Also, a full video image captured by the likes of a reversing camera ora forward facing night vision camera or a sidelane-monitoring camera canbe displayed on/via the vehicle windshield (or elsewhere) by the likesof a MicroHUD™ device and, conceptually, thus replacing the exteriormirrors with cameras. For example, a driver sidelane video image and apassenger sidelane video image, both preferably with graphic overlaysthereon, can be displayed at respective sides of the vehicle windshieldvia a MEMS-based display system (such as via a MicroHUD™ HUD displaydevice) and with the image visible to the driver by viewing the vehiclewindshield (such as via an optical image combiner created on the innerglass surface of the windshield and/or onto the polymeric laminatinginterlayer (typically a sheet of polyvinyl butyral or of silicone or thelike) utilized in the laminate windshield).

Optionally, a laser emitter or laser diode or the like may be positionedwithin the mirror casing and behind the reflective element, and may beused to emit radiation onto a reflector (such as amicroelectromechanical scanner (MEMS)) within the mirror casing thatreflects the radiation toward and through the mirror reflective elementfor viewing by a driver of the vehicle (such as by utilizing aspectsdescribed in U.S. patent application Ser. No. 10/225,851, filed Aug. 22,2002, now U.S. Pat. No. 6,847,487; and/or Ser. No. 11/105,757, filedApr. 14, 2005; and/or U.S. provisional application Ser. No. 60/607,963,filed Sep. 8, 2004, which are hereby incorporated herein by reference).

Such a laser scanning display device may provide enhanced displaycharacteristics for enhanced viewing of the display at the reflectiveelement by the driver of the vehicle. Typically, in order to use a laserto back light a display area (such as an area of about 2 cm square orthereabouts), the laser beam may be projected through an optic thatbroadens the beam to the desired size, whereby the intensity of the beamis reduced. An advantage of such scanning display technologies is theintensity of the display delivered, and so its ability to be seen evenunder high ambient driving conditions (such as a sunny day). Forexample, should a standard backlit TFT LCD display be placed behind atransflective mirror element in the likes of an interior rearview mirrorassembly, the front or first surface reflection off the front glasssurface (typically around 4 percent of the light incident thereon) oftenfar exceeds the intensity of the light transmitted through thetransflective mirror reflective element used. Such transflective mirrorsalso reflect coincident with the reflection off the front surface, andthus further exasperate the washout of the display image beingtransmitted/emitted through the reflective element. Even if thereflective coating is locally fully removed to create a lighttransmitting window, reflectivity off the front glass surface oftencauses display washout and inability to appropriately read what is beingviewed at the display. This is particularly problematic for videodisplay (such as for the likes of a rear backup event or side lanemaneuver event or the like).

Thus, one advantage of use of such a scanning display technology (suchas described in further detail below) is that the full intensity of thelaser is used, but by using the movable mirror/reflector of themicroelectromechanical scanner (MEMS), the narrow point like, super highintensity beam rapidly moves across the display image dimension at arate that is faster than the eye/brain can register, such that theeye/brain perceives a continuous (or substantially continuous) superbright image. Thus, using the concepts of the present invention asdescribed below, a full video image can effectively be projected throughor on a surface of the rearview mirror reflective element in a mannernot unlike what can be seen during outdoor laser displays or the like(such as when images and video is laser written on the sides ofbuildings or clouds or the like). Also, multiple lasers of the samecolor can be focused so that their beams coincide at roughly the samepoint on the MEMS reflector so that the intensity of any one imageelement as written is correspondingly enhanced.

For example, and with reference to FIG. 28, an interior rearview mirrorassembly 910 is pivotally or adjustably mounted to an interior portionof a vehicle, such as via a double ball mounting or bracket assembly912. Mirror assembly 910 includes an electro-optic or electrochromicreflective element 914 supported at or in a housing or casing 918. Themirror assembly 910 includes a scanning display device 926 that isoperable to display information (such as text, alphanumeric characters,icons, images, video images, or other indicia or information or thelike) at the reflective element 914 for viewing by a driver of thevehicle. Advantageously, display device 926 is housed behind (to therear of) the mirror reflective element and thus is within mirror casing918. Thus, the automaker may acquire and install mirror assembly 910(with the scanning display capability included) across a variety ofvehicle models and lines. Reflective element 914 includes a frontsubstrate 920 and a rear substrate 922 and an electro-optic medium 924disposed therebetween, and may comprise a transflective reflectiveelement that allows light from the display device 926 to passtherethrough for viewing by the driver of the vehicle, such as byutilizing principles described in U.S. Pat. Nos. 6,690,268; 5,668,663and/or 5,724,187, and/or in U.S. patent application Ser. No. 10/054,633,filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381; and/or Ser. No.11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451; and/or PCTApplication No. PCT/US03/29776, filed Sep. 9, 2003; and/or PCTApplication No. PCT/US03/35381, filed Nov. 5, 2003; and/or U.S.provisional applications, Ser. No. 60/630,061, filed Nov. 22, 2004; Ser.No. 60/667,048, filed Mar. 31, 2005; Ser. No. 60/629,926, filed Nov. 22,2004; Ser. No. 60/531,838, filed Dec. 23, 2003; Ser. No. 60/553,842,filed Mar. 17, 2004; and Ser. No. 60/563,342, filed Apr. 19, 2004,and/or PCT Application No. PCT/US03/40611, filed Dec. 19, 2003, whichare all hereby incorporated herein by reference. Optionally, use of anelemental semiconductor mirror, such as a silicon metal mirror, such asdisclosed in U.S. Pat. Nos. 6,286,965; 6,196,688; 5,535,056; 5,751,489and 6,065,840, and/or in U.S. patent application Ser. No. 10/993,302,filed Nov. 19, 2004, now U.S. Pat. No. 7,338,177, which are all herebyincorporated herein by reference, can be advantageous because suchelemental semiconductor mirrors (such as can be formed by depositing athin film of silicon) can be greater than 50 percent reflecting in thephotopic (SAE J964a measured), while being also substantiallytransmitting of light (up to 20 percent or even more). Such siliconmirrors also have the advantage of being able to be deposited onto aflat glass substrate and to be bent into a curved (such as a convex oraspheric) curvature, which is also advantageous since manypassenger-side mirrors are bent or curved. Optionally, the curvedreflective element or glass substrate may be formed by first taking flatglass sheets/shapes that are hydrophilic coated and then bending theglass sheets/shapes to from bent (convex or aspheric) sheets/shapes. Thebent sheets/shapes are non-crazed/optically clear after bending andstill maintain the hydrophilic property after bending. Optionally, thebent sheets/shapes can then also be coated with a transparent conductivematerial, such as an ITO material or the like, on their “second”surface, such that such a hydrophilic first surface coated andtransparent conductive material coated second surface substrate can beused as a front or first substrate in an electro-optic reflectiveelement or mirror cell, such as an electrochromic reflective element ormirror cell.

For example, sheets of hydrophilic coated glass may be procured, such asfrom various sources. For example, suitable bendable hyrdrophilic-coatedglass sheets are available from KUPO CO., LTD of Taipei, Taiwan underthe trade name ACTMIR. ACTMIR hyrdrophilic-coated glass can be activatedby exposure to ultraviolet (UV) irradiation (under 400 nm) that ispresent in sunlight. Low power ultraviolet irradiation (about 0.1 toabout 1.0 mW/CM2) is sufficient to activate ACTMIR's photocatalytichydrophilic capability. ACTMIR achieves its hydrophilic property using atitanium dioxide photocatalyst formed via nanoparticulate coatingtechnology. This nanomaterial coating layer(s) can be first bent at hightemperatures (typically about 700 Celsius or higher) without losing itscosmetic quality or hydrophilic capability, and then the benthydrophilic-coated glass can be coated on the side opposite to that ofthe hydrophilic layer(s) with a transparent conductor, such as ITO orthe like, that is typically deposited at temperatures of about 350 toabout 450 degrees Celsius or higher.

The flat sheets are thus brought to a glass bender and are bent toeither a convex or aspheric radius of curvature, but with the flat,hydrophilic coated glass loaded into the bender such that thehydrophilic coated surface is on the convex surface of the resultantbent sheet of glass. The hydrophilic coating or coatings selected andutilized are such that the coating or coatings can withstand the hightemperatures and mechanical stresses of a glass bending operation whilestill maintaining their hydrophilic property and propensity, and whilestill sustaining good cosmetic optical quality (such as little to nocrazing, flaking or other cosmetic optical degradation) through andafter the bending/annealing process. After being so bent, suchhydrophilic clear glass bent lites/mini-lites/shapes can be transparentconductive coated (such as with an ITO coating or the like) on theconcave surface and subsequently used in the manufacture of anelectrochromic reflective element or cell. Prior known hydrophilicelectrochromic manufacturing operations typically require coating of theconvex surface after glass bending. The ability to hydrophilic coat—thenbend (with the hydrophilic coating on the convex surface of the bentglass)—then ITO coat the concave surface—then EC cell manufacture hasadvantages in reduction of complexity and cost of the electrochromicreflective element or cell.

Display device 926 comprises a scanning beam display system thatincludes a plurality of laser light sources or diodes 928 a, 928 b, 928c, a controller 930 and a microelectromechanical scanner (MEMS) 932. Thedisplay device 926 is contained within the interior casing 918 of mirrorassembly 910. The controller 930 receives and/or generates image signalsthat control the intensity, mix and on-time of the light output by thethree laser diodes 928 a, 928 b, 928 c. The controller 930 alsoestablishes the coordinates for the movable elements of the MEMSassembly 932 so that the individual picture elements (pixels) of thedisplayed image are created for view by the driver or other vehicularoccupant. For monochrome (one-color) systems, only one laser diodesource may be used. Optionally, for full-color displays, three lightsources (e.g., red, green and blue) are modulated and merged to producean image element of the appropriate color. Under the control ofcontroller 930, a horizontal and vertical scanner or a singlemicroelectromechanical scanner (MEMS) 932 directs the light beamsreceived from laser diodes 928 a, 928 b, 928 c, and projects them ontothe rear of (and/or into the body of) mirror reflective element 914 tocreate the image viewed. Optics (not shown) may be included as desiredto achieve the desired spatial and resolution dimensions displayed.

For example, mirrors and/or lens elements or other refractive ordiffractive and/or reflective optical elements can be used to projectthe rapidly scanned beam or beams of light onto the rear of the mirrorelement (and/or into the body thereof) to create the image seen. Such ascanned-beam automotive mirror display can deliver very high resolution,very high intensity images, with the resolution being limitedprincipally by diffraction and optical aberrations in the light sourcesused within the mirror casing. Optionally, the rear surface 922 a of therear substrate 922 of the reflective element 914 may include a diffusercoating or layer/combiner 934 or other diffuser means or the like, andthe diffuser coating or layer or area may be over substantially theentire rear surface 922 a or may be over only that portion of the rearor fourth surface rastered by light reflected off the MEMS 932 thatcreates the display image. Also, and optionally, diffuser coatingsand/or layers/combiners may be included within the body of the mirrorreflective element, such as on the third surface of the electro-opticreflective element. Although illustrated as a transflective mirrorelement, the reflective coating may be locally removed from anon-transflective mirror element to create a window for viewing thedisplay thereat or therethrough. The window region may include a diffusecoating and/or layer/combiner or the like, such as on the rear surfaceof the reflective element (such as if the reflective element is anelectro-optic or electrochromic reflective element or anon-electro-optic or prismatic reflective element) or on the thirdsurface (such as if the reflective element is an electro-optic orelectrochromic reflective element), if desired.

The laser diodes may be rastered or scanned at a desired rate over theMEMS reflector so that a generally continuous image is created byreflection off the MEMS and onto/into and as viewed through thereflective element. In the illustrated embodiment, the laser diodes arepositioned to project or emit or radiate their laser beams so that theyare incident on the electromechanically moved portion of the MEMS andwhereby the laser beams are reflected toward the reflective element bythe MEMS reflector.

The MEMS 932 may be positioned within the casing and angled or orientedto reflect illumination or radiation from the laser diodes 928 a, 928 b,928 c toward the rear surface of the reflective element 914. Thereflective surface of the MEMS 932 may be created on a chip, and may beadjusted to provide the desired projection or reflection angle throughthe reflective element 914 for viewing by a driver of the vehicle. TheMEMS reflector may be electrically adjusted and/or electromechanicallyadjusted to provide the appropriate or desired information or icon orimage for the laser beams to project onto and through the reflectiveelement. The laser diodes 928 a, 928 b, 928 c may comprise any laserdiodes, such as, for example, laser diodes of the types commerciallyavailable from Cree Research Inc. of Durham, N.C., which offersdifferent color laser diodes, such as visible red laser diodes and/orblue laser diodes, such as gallium nitride based blue lasers, and othercolors as may be desired, such as green.

Because of the high intensity illumination provided by such laserdiodes, the intensity at the display region of the reflective elementwill be sufficient to dominate the reflection of the rearward scene offof the front surface of the front substrate of the reflective element,and thus will not appear washed out, even during high ambient lightingconditions, such as on a sunny day or the like. Optionally, theintensity of the laser diodes may be adjusted, such as via manualadjustment and/or via automatic adjustment, such as in response to theambient light levels in the cabin of the vehicle or in the vicinity ofthe display. The display information may be associated with anyaccessory or component or feature of the interior rearview mirrorassembly or of the vehicle, such as point-to-point navigationalinstructions, status information for various functions, such aspassenger side airbag status, tire pressure status and/or the like, orcompass heading or temperature information or other information or thelike.

Although shown and described as being incorporated into an electro-opticor electrochromic interior rearview mirror assembly, it is envisionedthat the scanning beam display system may be incorporated into aprismatic interior rearview mirror assembly or a transflective prismaticrearview mirror assembly (such as by utilizing principles described inPCT Application No. PCT/US03/29776, filed Sep. 19, 2003; U.S. patentapplication Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No.7,255,451; and/or Ser. No. 10/993,302, filed Nov. 19, 2004, now U.S.Pat. No. 7,338,177, which are all hereby incorporated herein byreference). Optionally, the laser scanning beam display system may beincorporated into an exterior rearview mirror assembly without affectingthe scope of the present invention. For exterior rearview mirrorapplications, the display system may function to display blind spotdetection icons or information, or turn signals or security lights orthe like, at the reflective element of the exterior rearview mirrorassembly of the vehicle. For example, a non-electro-optic/fixedreflectivity reflector may use an elemental semiconductor mirror, suchas a silicon metal mirror, such as disclosed in U.S. Pat. Nos.6,286,965; 6,196,688; 5,535,056; 5,751,489 and 6,065,840, and/or in U.S.patent application Ser. No. 10/993,302, filed Nov. 19, 2004, now U.S.Pat. No. 7,338,177, which are all hereby incorporated herein byreference, can be advantageous because such elemental semiconductormirrors (such as can be formed by depositing a thin film of silicon) canbe greater than 50 percent reflecting in the photopic (SAE J964ameasured), while being also substantially transmitting of light (up to20 percent or even more). Such silicon mirrors also have the advantageof being able to be deposited onto a flat glass substrate and to be bentinto a curved (such as a convex or aspheric) curvature, which is alsoadvantageous since many passenger-side mirrors are bent or curved.

Also, a video display and/or other information display may be located atthe interior mirror assembly (or at a windshield electronicsmodule/accessory module) that utilizes aMicro-Electro-Mechanical-Systems (MEMS) structure combined with thinfilm optics, such as is available Iridigm of San Francisco, Calif. underthe trade name iMoD™ technology. This display technology (such as isdescribed in U.S. Pat. Nos. 6,794,119; 6,741,377; 6,710,908; 6,680,792;6,674,562; 6,650,455; 6,589,625; 6,574,033; 5,986,796 and 5,835,255,which are hereby incorporated herein by reference) is designed todeliver lower power consumption and excellent display image quality, andcan withstand extreme temperatures and can be viewed in substantiallyany environment, including bright sunlight.

Optionally, and particularly for an exterior mirror reflective element,a display may be etched or formed or established through the mirrorreflector layer or coating and back lit via rear mounted light sourcesso as to illuminate the display indicia or icon. For example, FIGS. 35and 36 show an exterior electrochromic (EC) mirror unit that includes anindicator (such as a turn signal indicator such as is disclosed in U.S.Pat. No. 4,906,085, or a blind spot system alert indicator such asdisclosed in U.S. Pat. No. 5,313,335, the disclosures of which areincorporated by reference in their entireties herein) that is disposedto the rear of the EC reflector element so that light emitted by therear-disposed indicator shines through the EC medium to be viewed fromthe front of the EC mirror element when the rear-disposed indicatorlight source is illuminated. The EC reflective element typically ispowered by photosensors located at the interior mirror assembly withinthe cabin of the vehicle to which the exterior EC mirror unit ismounted. Such as is disclosed in U.S. Pat. No. 2,263,382, issued toGotzinger (the disclosure of which is incorporated by reference in itsentirety herein), when the light of the indicator light source behindthe EC mirror cell is turned on, there is illumination through a symbolscratched into the metallic reflector layer on the third surface of theEC cell (that may be constructed such as is disclosed in U.S. Pat. Nos.5,668,663; 5,724,187; 5,910,854 and/or 6,002,511, the disclosures ofwhich are incorporated by reference in their entireties herein) or in afourth surface reflector layer (such as disclosed in U.S. Pat. No.5,786,772, the disclosure of which is incorporated by reference in itsentirety herein). Such fine scratches or holes are created in the metalreflector layer such as by laser ablation. For example, and as shown inFIGS. 35 and 36, an ablating laser can be used to create fine scratchesor holes (such as fine circular holes or fine ovals or fine star-shapedholes or other designs of holes/scratches) by removing locally the likesof a rhodium/chromium or a silver or an ITO/silver/ITO or aruthenium/chromium metallic reflector layer to create a symbol (such asfor a blind spot indicator and/or a turn signal indicator). As describedin U.S. Pat. No. 2,263,382, issued to Gotzinger, the turn signal orblind spot symbol or icon is formed by an aggregation of fine scratchesor holes in the “silvering” of the mirror element so that when therear-disposed light (such as a red or amber light emitting diode or aplurality of light emitting diodes) is turned on, there is illuminationthrough the scratched lines/holes, which are so fine as to be hardlynoticeable to a viewer of the exterior mirror on the vehicle when notilluminated. Also, the illumination may be diffused in the scratches andpresents the appearance of a solid area of color/illumination.

Referring to FIGS. 35 and 36, an exterior mirror reflective element 950of an exterior rearview mirror assembly includes a glass substrate 952with a metallic mirror reflector layer or coating 954 (such as a coatingof rhodium/chromium or ruthenium chromium or a silver or anITO/silver/ITO or the like) disposed on a surface of the glass substrate(such as on a front or third surface of a rear substrate of anelectrochromic reflective element or on a front or rear surface of asingle substrate reflector). Note that the glass substrate can form arear substrate for an electro-optic, such as electrochromic, reflectiveelement, such as the glass substrates 952′, 952″ shown in FIGS. 39 and40 (discussed below), whereupon mirror reflective layer or coating 952′,952″ would constitute a third surface reflector, or the glass substrate(such as glass substrate 952 shown in FIGS. 35 and 36) may be a singlesubstrate mirror reflector element (commonly chrome coated or the like)whereupon metallic reflector layer or coating 954 may be a first surfacereflector layer or a second surface reflector layer, depending on thepreference of a particular automaker. A plurality of fine holes orscratches or ports 956 may be scratched or established through thereflector coating 954 and in clusters 958 that cooperate to define aniconistic display or indicia 960, such as a turn signal symbol or icon.The exterior rearview mirror assembly includes one or more illuminationsources disposed behind the reflective element and activatable orenergizable to emit illumination that passes or transmits through thescratches 956 so as to be viewable be a person viewing the reflectiveelement of the exterior mirror assembly. As shown in FIG. 36, thescratches or holes 956 may be spaced apart with portions 954 a of thereflector coating 954 therebetween, and may have inter-spacing betweenadjacent scratches or holes and preferably having the inter-spacespacing or distance between adjacent scratches or holes being greaterthan the width/diameter dimension of the individual scratches/holes. Forexample, the scratches may have a diameter or width dimension of about0.1 mm to about 0.2 mm, and may aggregate in locally clusteredscratches/holes, with the scratches/holes being inter-spaced about 0.2mm to about 0.3 mm apart from one another. Although shown and describedas being formed or established at an exterior rearview mirror reflectiveelement, aspects of the fine scratched surface and indicia/symboldescribed above may applicable to interior rearview mirror assemblyapplications, without affecting the scope of the present invention.Optionally, a photo sensor or photodiode or the like may be positionedwithin the mirror assembly and generally behind one or more of the finescratches so as to sense glare and/or ambient light through the finescratch or scratches, without affecting the scope of the presentinvention.

As illustrated in FIGS. 37A, 37B, the fine scratches may be selectivelyspaced apart so as to provide a desired packing area and consequentlocal light transmission. Referring to FIG. 37A, circles or scratchesthat are substantially adjacent to or abutting one another form aclosest packing. More preferably, and as shown in FIG. 37B, individualscratches or holes in the metallic reflector coating or layer are spacedapart (by a spacing dimension (a) in FIG. 37B), so that the mirrorreflector coating is present between the scratches. Note that thespacing dimension (a) may or may not be equal to scratch size dimension(b). Optionally, the spacing dimension may be greater than the diameteror width dimension of the scratches/holes. The desired lighttransmission of light from the illumination source disposed behind themirror element and shining through the cluster of fine scratches isprincipally determined by the width or diagonal or cross dimension (d)of the scratches and the interspace spacing dimension (a) between thescratches. The light transmission ratio may be crudely estimated as afunction of the diameter (d) (or width or other dimension or crossdimension) of the scratches and the inter-spacing distance (a) betweenthe scratches. More particularly, the light transmission ratio iscalculated via the following equation: % T=4d²/(a²+4ad+4d²)%. Varioushole sizes and spacing distances and transmission ratios are shown inthe table of FIG. 38.

Optionally, and as shown in FIGS. 39 and 40, the clusters 958′, 958″ maybe established in a third surface reflector coating or layer 954′, 954″of an electro-optic reflective element 950′, 950″, with an indicator orillumination source 960′, 960″ positioned behind the rear substrate952′, 952″ and operable to transmit illumination through the rearsubstrate 952′, 952″, the scratches/holes 956′, 956″, the electrochromicmedium 962 and the front substrate 964 (which has a transparentconductive coating 966, such as an ITO or the like, on its rear orsecond surface). As shown in FIG. 39, the illumination source 960′ maycomprise a plurality of LEDs or the like positioned rearward of a lightdirectional filter 968′ on the rear surface of the rear substrate 952′so as to direct light from the LEDs in a desired direction, such asgenerally toward the driver of the host vehicle for anobject-in-a-blind-spot alert system or the like (or generally away fromthe driver of the host vehicle for a turn signal indicator). Likewise,and with reference to FIG. 40, the illumination source 960″ may belocated at a directional tube 970″ that is angled to direct theillumination in the desired direction (such as generally toward thedriver of the vehicle for an object-in-a-blind-spot alert system or thelike or generally away from the driver of the host vehicle for a turnsignal indicator). As shown in FIG. 40, a mask 972″ may be provided atthe rear surface of the rear substrate 952″ to define the blindspotalert icon (such as an ISO icon or the like). The directional tube andindicator may utilize aspects of the indicator device described in U.S.provisional application Ser. No. 60/171,093, filed Sep. 14, 2005, whichis hereby incorporated herein by reference. The illumination source orsources and the light directing film and/or light directing structure ortube thus function to provide a directional display that is principallyviewable by a person viewing the reflective element along the directionof the principle axis of light transmitting through the reflectiveelement.

Depending on the fineness of the scratches (about 0.075 mm to about 0.3mm width/diameter preferred; about 0.1 mm to about 0.25 mmwidth/diameter more preferably; about 0.15 mm to about 0.22 mmwidth/diameter most preferably) and their packing density relative toeach other (a scratch/hole inter-space distance of about 0.075 mm toabout 0.3 mm preferred; about 0.1 mm to about 0.25 mm more preferably;about 0.15 mm to about 0.22 mm most preferably), the effectivetransmission through the local fine scratched symbol or icon can varyfrom about 10 percent transmission for visible light to about 40 percent(because the packing density of the clustered light-transmitting holesscratched in the mirror reflector layer to locally-adjacentsubstantially non-light transmitting non-scratched mirror reflectorlayer coating is about 10 percent to about 40 percent). In general, itis preferable to have a percent transmission or percent transmitting orpercent transmissivity for such Gotzinger-based fine-scratched symbol tobe about 10 percent to about 20 percent (about 12 percent to about 17percent more preferred; about 13 percent to about 16 percent mostpreferred), as this makes the symbol particularly hardly noticeablewhile preserving local average reflectivity (at least about 40 percentaverage local preferred, more preferably at least about 50 percent andmost preferably at least about 60 percent). For example, and as seen inthe table in FIG. 38, a scratch/hole width or diameter of about 0.8 mmto about 0.25 mm and an inter-spacing of about 0.3 mm to about 0.5 mmcan give a percent transmission through the blind spot symbol or throughthe turn signal symbol/icon of about 10 percent transmission to about 20percent transmission while still having the presence of the symbollargely unnoticeable to a viewer unless the rear-disposed indicatorlight source is illuminated by applying electrical power, and whilelocally preserving an average of at least about 50 percent transmissionat the fine scratched surface. Naturally, and depending on theparticular mirror constructions involved and on the light intensityoutput of rear-disposed light sources, other scratch or hole sizesand/or inter-space dimensions may be contemplated. In general, it ispreferred to have a ratio of the spacing between scratches/holesdimension to the dimension of the scratch/hole itself be at leastgreater than about 1.1, more preferably greater than about 2, and mostpreferably greater than about 4; but it is also preferred to have theratio of the spacing between scratches/holes dimension to the dimensionof the scratch/hole itself be less than about 7, more preferably lessthan about 6, and most preferably less than about 5.

Changes and modifications to the specifically described embodiments maybe carried out without departing from the principles of the presentinvention, which is intended to be limited only by the scope of theappended claims as interpreted according to the principles of patentlaw.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A multi-camera visionsystem for a vehicle, said multi-camera vision system comprising: arear-mounted video camera at a rear portion of a vehicle equipped withsaid multi-camera vision system; said rear-mounted video camera havingat least a rearward field of view external of the equipped vehicle; saidrear-mounted video camera operable to capture video image data at leastrearward of the equipped vehicle during a maneuver of the equippedvehicle; a front-mounted video camera at a front portion of the equippedvehicle; said front-mounted video camera having at least a forward fieldof view external of the equipped vehicle; said front-mounted videocamera operable to capture video image data at least forward of theequipped vehicle during the maneuver of the equipped vehicle; a firstside-mounted video camera at a driver-side side portion of the equippedvehicle; said first side-mounted video camera having at least a sidewardfield of view external of the equipped vehicle; said first side-mountedvideo camera operable to capture video image data at least sideward ofthe equipped vehicle during the maneuver of the equipped vehicle; asecond side-mounted video camera at a passenger-side side portion of theequipped vehicle; said second side-mounted video camera having at leasta sideward field of view external of the equipped vehicle; said secondside-mounted video camera operable to capture video image data at leastsideward of the equipped vehicle during the maneuver of the equippedvehicle; a display device comprising a video screen operable to displayvideo images for viewing by a driver of the equipped vehicle who isoperating the equipped vehicle; a central data processor disposed in theequipped vehicle; wherein captured image data is provided to saidcentral data processor; wherein image data captured by saidfront-mounted video camera, said first side-mounted video camera, saidsecond side-mounted video camera and said rear-mounted video camera isprocessed at said central data processor to generate video images fordisplay on said video screen that inform the driver of the environmentin which the equipped vehicle is being operated; wherein image datacaptured by said front-mounted video camera, said first side-mountedvideo camera, said second side-mounted video camera and saidrear-mounted video camera is processed at said central data processor inorder to detect objects that are within the combined field of view ofsaid front-mounted video camera, said first side-mounted video camera,said second side-mounted video camera and said rear-mounted videocamera; wherein detection of objects via processing at said central dataprocessor of captured image data comprises use of an edge detectionalgorithm; wherein the equipped vehicle is further equipped with atleast one non-visual sensor selected from the group consisting of (i) aradar sensor and (ii) an ultrasonic sensor; wherein said at least onenon-visual sensor captures sensor data in a region external of theequipped vehicle; wherein captured sensor data is provided to saidcentral data processor; wherein an alert to the driver of the equippedvehicle is generated when, via processing at said central data processorof at least one of received image data and received sensor data, apotential hazard is determined to exist; and wherein said rear-mountedvideo camera has a field of view that encompasses at least a portion ofa vehicle bumper of the equipped vehicle.
 2. The multi-camera visionsystem of claim 1, wherein said display device is disposed at aninterior rearview mirror assembly of the equipped vehicle and wherein atleast one of (a) said display device displays video images for viewingthrough a mirror reflective element of said interior rearview mirrorassembly by the driver of the equipped vehicle and (b) said displaydevice automatically extends from said interior rearview mirror assemblyresponsive to the vehicle transmission being shifted into reverse gear,and wherein said interior rearview mirror assembly comprises a moldedplastic mounting arm having at least one ball member at at least one endthereof and having electrical conducting elements extendingtherethrough, and wherein a mirror mounting portion is molded over saidball member, and wherein said mounting arm comprises a mounting armpolymeric material having a first linear mold shrinkage factor and afirst flexural modulus, and wherein said mirror mounting portioncomprises a mirror mounting polymeric material having a second linearmold shrinkage factor and a second flexural modulus, and wherein saidsecond linear mold shrinkage factor is greater than said first linearmold shrinkage factor, and wherein said second flexural modulus is lowerthan said first flexural modulus.
 3. The multi-camera vision system ofclaim 1, wherein said rear-mounted video camera comprises a rear backupcamera and wherein an overlay is displayed with video images captured bysaid rear backup camera to guide the driver when hitching a trailer to atrailer hitch of the equipped vehicle.
 4. The multi-camera vision systemof claim 3, wherein said overlay aids in guiding connection of thetrailer hitch of the equipped vehicle to a trailer tongue of thetrailer.
 5. The multi-camera vision system of claim 1, wherein saidvideo screen of said display device comprises a backlit thin filmtransistor LCD video screen backlit by a plurality of white lightemitting light emitting diodes.
 6. The multi-camera vision system ofclaim 5, wherein said plurality of white light emitting light emittingdiodes comprises an array of at least four white light emitting lightemitting diodes.
 7. The multi-camera vision system of claim 6, whereinsaid display device is operable to display video images with a displayintensity, as viewed by the driver of the equipped vehicle, greater than200 candelas/sq. meter.
 8. The multi-camera vision system of claim 6,wherein said display device is operable to display video images with adisplay intensity, as viewed by the driver of the equipped vehicle,greater than 400 candelas/sq. meter.
 9. The multi-camera vision systemof claim 1, wherein said rear-mounted video camera comprises a rearbackup camera.
 10. The multi-camera vision system of claim 1, whereindata is provided to said central data processor via a vehicle network ofthe equipped vehicle.
 11. The multi-camera vision system of claim 1,wherein said potential hazard arises from presence of rear-approachingtraffic in side and rear lanes to the equipped vehicle.
 12. Themulti-camera vision system of claim 11, wherein an alert to the driverof the equipped vehicle is generated when, via processing at saidcentral data processor of received image data and received sensor data,a potential hazard is determined to exist.
 13. The multi-camera visionsystem of claim 1, wherein said at least one non-visual sensor comprisesa radar sensor.
 14. The multi-camera vision system of claim 1, whereinsaid at least one non-visual sensor comprises an ultrasonic sensor. 15.The multi-camera vision system of claim 14, wherein said sensor detectsthe presence of an obstacle exterior the equipped vehicle.
 16. Themulti-camera vision system of claim 15, wherein said rear-mounted videocamera comprises a CMOS imaging array and wherein said central dataprocessor processes fused image and sensor data.
 17. A multi-cameravision system for a vehicle, said multi-camera vision system comprising:a rear-mounted video camera at a rear portion of a vehicle equipped withsaid multi-camera vision system; said rear-mounted video camera havingat least a rearward field of view external of the equipped vehicle; saidrear-mounted video camera operable to capture video image data at leastrearward of the equipped vehicle during a maneuver of the equippedvehicle; a front-mounted video camera at a front portion of the equippedvehicle; said front-mounted video camera having at least a forward fieldof view external of the equipped vehicle; said front-mounted videocamera operable to capture video image data at least forward of theequipped vehicle during the maneuver of the equipped vehicle; a firstside-mounted video camera at a driver-side side portion of the equippedvehicle; said first side-mounted video camera having at least a sidewardfield of view external of the equipped vehicle; said first side-mountedvideo camera operable to capture video image data at least sideward ofthe equipped vehicle during the maneuver of the equipped vehicle; asecond side-mounted video camera at a passenger-side side portion of theequipped vehicle; said second side-mounted video camera having at leasta sideward field of view external of the equipped vehicle; said secondside-mounted video camera operable to capture video image data at leastsideward of the equipped vehicle during the maneuver of the equippedvehicle; a display device comprising a video screen operable to displayvideo images for viewing by a driver of the equipped vehicle who isoperating the equipped vehicle a central data processor disposed in theequipped vehicle; wherein captured image data is provided to saidcentral data processor; wherein image data captured by saidfront-mounted video camera, said first side-mounted video camera, saidsecond side-mounted video camera and said rear-mounted video camera isprocessed at said central data processor to generate video images fordisplay on said video screen that inform the driver of the environmentin which the equipped vehicle is being operated; wherein image datacaptured by said front-mounted video camera, said first side-mountedvideo camera, said second side-mounted video camera and saidrear-mounted video camera is processed at said central data processor inorder to detect objects that are within the combined field of view ofsaid front-mounted video camera, said first side-mounted video camera,said second side-mounted video camera and said rear-mounted videocamera; wherein detection of objects via processing at said central dataprocessor of captured image data comprises use of an edge detectionalgorithm; wherein the equipped vehicle is further equipped with atleast one non-visual sensor selected from the group consisting of (i) aradar sensor and (ii) an ultrasonic sensor; wherein said at least onenon-visual sensor captures sensor data in a region external of theequipped vehicle; wherein captured sensor data is provided to saidcentral data processor; wherein an alert to the driver of the equippedvehicle is generated when, via processing at said central data processorof at least one of received image data and received sensor data, apotential hazard is determined to exist; wherein said potential hazardarises from presence of rear-approaching traffic in side and rear lanesto the equipped vehicle; and wherein data is provided to said centraldata processor via a vehicle network of the equipped vehicle.
 18. Themulti-camera vision system of claim 17, wherein said video screen ofsaid display device comprises a backlit thin film transistor LCD videoscreen backlit by a plurality of white light emitting light emittingdiodes and wherein said plurality of white light emitting light emittingdiodes comprises an array of at least four white light emitting lightemitting diodes, and wherein said display device is operable to displayvideo images with a display intensity, as viewed by the driver of theequipped vehicle, greater than 200 candelas/sq. meter.
 19. Themulti-camera vision system of claim 18, wherein said rear-mounted videocamera comprises a rear backup camera and wherein said rear backupcamera has a field of view that encompasses at least a portion of avehicle bumper of the equipped vehicle.
 20. The multi-camera visionsystem of claim 19, wherein an alert to the driver of the equippedvehicle is generated when, via processing at said central data processorof received image data and received sensor data, a potential hazard isdetermined to exist.
 21. The multi-camera vision system of claim 20,wherein said rear-mounted video camera comprises a CMOS imaging arrayand wherein said central data processor processes fused image and sensordata.
 22. A multi-camera vision system for a vehicle, said multi-cameravision system comprising: a rear-mounted video camera at a rear portionof a vehicle equipped with said multi-camera vision system; saidrear-mounted video camera having at least a rearward field of viewexternal of the equipped vehicle; said rear-mounted video cameraoperable to capture video image data at least rearward of the equippedvehicle during a maneuver of the equipped vehicle; a front-mounted videocamera at a front portion of the equipped vehicle; said front-mountedvideo camera having at least a forward field of view external of theequipped vehicle; said front-mounted video camera operable to capturevideo image data at least forward of the equipped vehicle during themaneuver of the equipped vehicle; a first side-mounted video camera at adriver-side side portion of the equipped vehicle; said firstside-mounted video camera having at least a sideward field of viewexternal of the equipped vehicle; said first side-mounted video cameraoperable to capture video image data at least sideward of the equippedvehicle during the maneuver of the equipped vehicle; a secondside-mounted video camera at a passenger-side side portion of theequipped vehicle; said second side-mounted video camera having at leasta sideward field of view external of the equipped vehicle; said secondside-mounted video camera operable to capture video image data at leastsideward of the equipped vehicle during the maneuver of the equippedvehicle; a display device comprising a video screen operable to displayvideo images for viewing by a driver of the equipped vehicle who isoperating the equipped vehicle a central data processor disposed in theequipped vehicle; wherein captured image data is provided to saidcentral data processor; wherein image data captured by saidfront-mounted video camera, said first side-mounted video camera, saidsecond side-mounted video camera and said rear-mounted video camera isprocessed at said central data processor to generate video images fordisplay on said video screen that inform the driver of the environmentin which the equipped vehicle is being operated; wherein image datacaptured by said front-mounted video camera, said first side-mountedvideo camera, said second side-mounted video camera and saidrear-mounted video camera is processed at said central data processor inorder to detect objects that are within the combined field of view ofsaid front-mounted video camera, said first side-mounted video camera,said second side-mounted video camera and said rear-mounted videocamera; wherein detection of objects via processing at said central dataprocessor of captured image data comprises use of an edge detectionalgorithm; wherein the equipped vehicle is further equipped with anultrasonic sensor; wherein said ultrasonic sensor captures sensor datain a region external of the equipped vehicle; wherein captured sensordata is provided to said central data processor; wherein an alert to thedriver of the equipped vehicle is generated when, via processing at saidcentral data processor of at least one of received image data andreceived sensor data, a potential hazard is determined to exist; whereinsaid rear-mounted video camera has a field of view that encompasses atleast a portion of a vehicle bumper of the equipped vehicle; whereinsaid rear-mounted video camera comprises a rear backup camera andwherein video images captured by said rear backup camera are displayedon said video screen when a transmission of the equipped vehicle isshifted into reverse gear by the driver of the equipped vehicle; whereinsaid video screen of said display device comprises a backlit thin filmtransistor LCD video screen backlit by a plurality of white lightemitting light emitting diodes; wherein said plurality of white lightemitting light emitting diodes comprises an array of at least four whitelight emitting light emitting diodes; and wherein an overlay isdisplayed with video images captured by said rear backup camera to guidethe driver when hitching a trailer to a trailer hitch of the equippedvehicle.
 23. The multi-camera vision system of claim 22, wherein saidalert is generated via a rumble/vibration transducer.
 24. Themulti-camera vision system of claim 22, wherein display on said videoscreen of video images captured by said rear-mounted video cameracontinues during short term forward movement of the equipped vehicle.25. The multi-camera vision system of claim 24, wherein said displaydevice is operable to display video images captured by said rear-mountedvideo camera with a display intensity, as viewed by the driver of theequipped vehicle, greater than 200 candelas/sq. meter.
 26. Themulti-camera vision system of claim 25, wherein data is provided to saidcentral data processor via a vehicle network of the equipped vehicle.27. The multi-camera vision system of claim 22, wherein said rear backupcamera comprises a CMOS imaging array and wherein said central dataprocessor processes fused image and sensor data.
 28. The multi-cameravision system of claim 22, wherein said potential hazard arises frompresence of rear-approaching traffic in side and rear lanes to theequipped vehicle.
 29. The multi-camera vision system of claim 28,wherein an alert to the driver of the equipped vehicle is generatedwhen, via processing at said central data processor of received imagedata and received sensor data, a potential hazard is determined toexist.
 30. The multi-camera vision system of claim 28, wherein said rearbackup camera has a field of view that encompasses at least a portion ofa vehicle bumper of the equipped vehicle.